400-660LC42003 REPAIR MANUAL REPARATURANLEITUNG MANUALE DI RIPARAZIONE MANUEL DE RÉPARATION ART.NR.: 3.206.006-E MANUAL DE REPARACIÓN KTM Group Partner 400-660LC4 REPAIR MANUAL 1 SERVICE-INFORMATIONS 2 GENERAL INFORMATION 3 REMOVING AND REFITTING ENGINE 4 DISASSEMBLING THE ENGINE 5 SERVICING ON INDIVIDUAL COMPONENTS 6 ASSEMBLING THE ENGINE 7 ELECTRICAL 8 FUEL SYSTEM 9 TROUBLE SHOOTING 10 TECHNICAL SPECIFICATIONS 11 PERIODIC MAINTENANCE SCHEDULE 12 WIRING DIAGRAMS 13 14 15 16 I M P O RTA N T I N F O R M AT I O N /U P D AT I N G INSTRUCTIONS To be able to continue using the existing loose-leaf repair instructions, simply print the following pages and insert them in the existing repair instructions: 15-18, 20-28, 32, 35, 40-54, 64, 66-69, 73, 77, 79-81, 84-207, 219, 280-291, 314-319, 323, 378-387 Remove page (s) Replace by page (s) Insert page (s) 2-1C to 2-3C 2-1D to 2-3D 2-5C to 2-11C 2-6D to 2-13D 3-3 3-3D 4-1A 4-1D 4-5 to 4-16 4-5D to 4-17D 5-1A to 5-2A 5-1D to 5-2D 5-12 5-12D 5-14B to 5-17 5-14D to 5-17D 5-21 / 5-25 5-21D / 5-25D 6-1A to 6-2 6-1D to 6-2D 6-5C to 6-19C 6-5D to 6-21D 7-1 to 7-49C 7-1D to 7-51D 8-1C to 8-37C 8-1D to 8-49D 9-1 9-1D 10-1.1C 10-2D 10-62D to 10-72D 11-1C 11-1D 11-22D to 11-27D 12-2C 12-2D 12-57D to 12-66D after page 2-5D KTM REPAIR MANUAL IN LOOSE-LEAF FORM STORING THE REPAIR MANUAL IN THE BINDER – Put the index into the binder. – Put the front page of the repair manual (210x297 mm) into the transparent pocket provided for this purpose on the outside of the binder. – Put the spine label (170x45 mm) into the transparent pocket provided for this purpose on the spine of the binder. – Put the summary list of contents (150x297 mm) into the transparent pocket provided for this purpose on the inside of the binder or insert this page on the beginning of the manual. – Then insert the individual chapters of the manual between the sheets of the index according to the page number printed in the right bottom corner of each page. Example: page no. 3-5 3 = chapter 3 5 = page 5 All pages with a page number that begins with the digit 3, for example, must be put under the index heading „Chapter 3“. – Index sheets that have not been marked with a certain chapter are for your personal convenience. The respective headings can be entered in the list of contents. E X P L A N AT I O N - U P D AT I N G 3.205.49-E Repair Manual LC4 6/1998 Basicversion Modelyear 1998 (Engine number with first digit „8“) 3.205.73-E Updating of Rep.Manual LC4 7/1999 Modelyear 1999 (Engine number with first digit „9“) Art.-Nr. 3.206.006 -E 3.205.89-E Updating of Rep.Manual LC4 9/2000 Modelyear 2000/2001 (Engine number with first digit „0“ and „1“) 3.210.30-E Updating of Rep.Manual LC4 12/2001 Modelljahr 2002 (Engine number with first digit „2“) 3.206.006-E Updating of Rep.Manual LC4 4/2003 Repair manual KTM LC4 Modelljahr 2003 (Engine number with first digit „3“) Modification / Updating: Special tools, hydraulic clutch, Keihin carburator, technical details model 2003, technical specification, Maintenance schedule and wiring diagrams for modell 2003 Edition 4/2003 INTRODUCTION This repair manual offers extensiv repair-instructions and is an up-to-date version that describes the latest models of the series. However, the right to modifications in the interest of technical improvement is reserved without updating the current issue of this manual. A description of general working modes common in work shops has not been included. Safety rules common in the work shop have also not been listed. We take it for granted that the repairs are made by qualified profesionally trained mechanics. Read through the repair manual before beginning with the repair work. WARNING STRICT COMPLIANCE WITH THESE INSTRUCTIONS ESSENTIAL TO AVOID DANGER TO LIFE AND LIMB. ! CAUTION IS ! NON-COMPLIANCE WITH THESE INSTRUCTIONS CAN LEAD TO DAMAGE OF MOTORCYCLE COMPONENTS OR RENDER MOTORCYCLES UNFIT FOR TRAFFIC ! „NOTE” POINTS OUT USEFUL TIPS. Use only ORIGINAL KTM SPARE PARTS when replacing parts. The KTM high performance engine is only able to meet user expectations if the maintenance work is performed regularly and professionally. KTM Austria’s certificate of achievement for its quality system ISO 9001 is the beginning of an ongoing total reengineered quality plan for a brighter tomorrow. KTM Sportmotorcycle AG 5230 Mattighofen, Austria All design and assembly modification rights reserved. C by KTM SPORTMOTORCYCLE AG, AUSTRIA All rights reserved REPLY FAX FOR REPAIR MANUALS We have made every effort to make our repair manuals as accurate as possible but it is always possible for a mistake or two to creep in. To keep improving the quality of our repair manuals, we request mechanics and shop foremen to assist us as follows: If you find any errors or inaccuracies in one of our repair manual – whether these are technical errors, incorrect or unclear repair procedures, tool problems, missing technical data or torques, inaccurate or incorrect translations or wording, etc. – please enter the error(s) in the table below and fax the completed form to us at 0043/7742/6000/5349. NOTE to table: Enter the complete item no. for the repair manual in column 1 (e.g.: 3.210.66-E). You will find the number on the cover page or in the left margin on each right page of the manual. – – Enter the corresponding page number in the repair manual (e.g.: 5-7c) in column 2. – Enter the current text (inaccurate or incomplete) in column 3 by quoting or describing the respective passage of the text. If your text deviates from the text contained in the repair manual, please write your text in German or English if possible. – Enter the correct text in column 4. Your corrections will be reviewed and incorporated in the next issue of our repair manual. Item no. of repair manual Page Current text Correct text Additional suggestions, requests or comments on our Repair Manuals (in German or English): Name mechanic/shop foreman Company/work shop 2-1D 2 GENERAL INFORMATION INDEX Repair manual KTM LC4 Art.-Nr. 3.206.006 -E MODELS WITHOUT FRAME OIL CHANGING THE ENGINE OIL . . . . . CHANGING THE OIL FILTER . . . . . . CHANGING THE MICROFILTER . . . OIL CIRCUIT . . . . . . . . . . . . . . . . . OIL CIRCUIT 660 SMC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2 .2-2 .2-3 .2-4 .2-5 MODELS WITH FRAME OIL CHANGING THE ENGINE OIL . . . . . . CHANGING THE FINE SCREEN FILTER CHANGING THE OIL FILTER . . . . . . . OIL CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-6 .2-6 .2-7 .2-8 SECONDARY AIR SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-9 EPC-SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-10 SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-11 BLEEDING OF THE HYDRAULIC CLUTCH . . . . . . . . . . . . . . . . . . . . . . . .2-13 2-2D up to Modell 2001 from Modell 2002 on A A 1 Changing the engine oil (models without frame oil) NOTE: The engine oil change is to be carried out when the engine is still warm. WARNING AN ENGINE HAVING BEEN RUN WARM, AND THE ENGINE OIL IN IT ARE VERY HOT DO NOT BURN YOURSELF. - – Place the motorbike on a horizontal surface. Remove the two plugs (1 and 2), and drain oil into a container. NOTE: A third plug was installed in the 660 SMC model. Tightening torque: 20 Nm 1 2 2 ! THE SCREW PLUG CAUTION ! A MUST NOT BE REMOVED, THIS IS PART OF THE BY-PASS VALVE. – Clean the plugs thoroughly with a fireproof solvent and compressed air, in order to remove the metal abrasion. – After all the oil has drained through, clean raised and flat faces and install plugs with seals. Tighten plug 1 with 30 Nm (22 ft.lb) and plug 2 with 20 Nm (15ft.lb). – Remove the oil dipstick at the clutch cover, pour in engine oil and replace the oil dipstick. Oil capacity (up to model 2002) : 1.40 l Oil capacity (from model 2003 on) : 1.50 l Changing the oil filter Replace the oil filter when changing the engine oil. – Press the foot brake pedal and place a screwdriver or similar between foot brake pedal and stopper roll so that the oil filter cover is more accessible. – Remove banjo bolt 3 and the three bolts 4. – Remove oil filter cover 5 and oil filter. – Clean filter housing, oil filter cover and sealing surfaces. Check oil duct in oil filter cover if clogged. Art.-Nr. 3.206.006 -E 5 3 4 – Press the new O-ring 6 into the groove of the filter cover (if necessary fix with grease). Mount a new oil filter 7 on the connection piece of the oil filter cover an mount the whole unit. 3 5 NOTE: From model 2001 onwards the gasket 8 is mounted with a changed filter cover 5. If the new gasket 8 should be used on older engines, the filter cover must be flat regrinded or renewed (see Technical Info Nr. 0201/30/01). 6 Repair manual KTM LC4 4 8 7 – Mount three bolts and tighten with 5 Nm (4 ft.lb). – Mount hollow bolt with seal rings and tighten with 15 Nm (11 ft.lb). 2-3D Changing the microfilter 1 2 Replace the microfilter while changing the engine oil. – To do so, remove bolts 1 and take off the microfilter cover 2. – Remove the microfilter, clean its parts and check the O-ring on the microfilter cover for signs of damage. – Insert a new microfilter into the filter housing, tilt the motorcycle sideways and fill the microfilter housing with engine oil. – Slightly grease the O-ring and mount the microfilter cover. Then put the motorcycle back on its stand. 1 – It is necessary to bleed the microfilter so that all lubricating points can be quickly supplied with engine oil. – To do this, fill with oil and remove the jet screw from the oil line on the clutch cover. – Start the engine and close off the bore on the clutch cover with a rag. – Allow the engine to run at idle until oil runs out of the oil line 3. – Turn off the engine. Mount the jet screw, using two new seal rings. – Torque the jet screw to 10 Nm and check for leaks. 3 – Start the engine and let it idle for 1 - 2 minutes. ! CAUTION ! DO NOT REV UP THE ENGINE IMMEDIATELY AFTER AN OIL CHANGE ! KEEP IN MIND THAT IT TAKES SOME TIME UNTIL ALL LUBRICATING POINTS ARE PROPERLY PROVIDED WITH ENGINE OIL. JASO T903 MA TEMPERATURE 0°C 32°F 5W/40 10W/50 – Allow the engine to run until warm. Then, turn off the engine, and place the motorbike on a flat, level surface in an upright position (center stand). Wait for 5 minutes. Unscrew and remove the oil dipstick, and wipe it clean with a cloth. – Screw the dipstick in all the way and remove it again. The oil level should be between the two marks on the oil dipstick, however, it must never rise above the MAX mark. Otherwise, engine oil would get into the air filter box by way of the engine venting system. Add engine oil, if necessary. – Finally, check oil system and engine for leaks. ! CAUTION ! – ONLY – – USE HIGH-QUALITY OILS MEETING OR SURPASSING THE QUALITY REQUIREMENTS OF JASO T903 MA (FOR SPECIFICATIONS SEE CONTAINERS). INSUFFICIENT OIL OR POOR QUALITY OIL RESULTS IN PREMATURE WEAR OF THE ENGINE. YOU MAY USE EITHER MINERAL OILS OR SYNTHETIC OILS FULFILLING THE ABOVE CRITERIA. NOTE: Dispose of used oil properly ! Under no circumstances may used oil be disposed of in the sewage system or in the open countryside. 1 liter oil contaminates 1.000.000 liter water. 2-4D Oil circuit The oil pump 1 pumps the engine oil past the by-pass valve 2 through the oil filter 3. After the oil filter, an oil lead branches off to a jet 4 which sprays engine oil onto the piston pin bearing and piston head. The second oil lead takes the main flow of oil to the microfilter 5, which filters out even the finest impurities. The cleaned engine oil is pumped through the oil lead and the clutch cover into the crankshaft to the connecting rod bearing 6 and drips into the crankcase. An additional oil pump 7 sucks the engine oil out of the crankcase and pumps it through the oil line 8 to the gear wheels of the 4th and 5th gear. Via the gear wheels, the engine oil reaches the oil sump. The timing chain 9 runs through the oil sump and transports the engine oil upwards to the cylinder head. Through the bore bk the oil reaches the camshaft bl and the valves. 10 11 9 4 Art.-Nr. 3.206.006 -E 6 7 8 3 1 Repair manual KTM LC4 2 5 2-5D Oil circuit 660 SMC The oil pump 1 pumps the engine oil past the by-pass valve 2 through the oil filter 3. After the oil filter, an oil lead branches off to a jet 4 which sprays engine oil onto the piston pin bearing and piston head. The second oil lead takes the main flow of oil to the second jet 4 and the microfilter 5, which filters out even the finest impurities. The cleaned engine oil is pumped through the oil lead and the clutch cover into the crankshaft to the connecting rod bearing 6 and drips into the crankcase. An additional oil pump 7 sucks the engine oil out of the crankcase and pumps it through the oil line 8 to the gear wheels of the 4th and 5th gear. Via the gear wheels, the engine oil reaches the oil sump. The timing chain 9 runs through the oil sump and transports the engine oil upwards to the cylinder head. Through the bore bk the oil reaches the camshaft bl and the valves. 10 11 9 6 4 4 7 8 3 1 2 5 2-6D Changing the engine oil (models with frame oil) NOTE: For improved cooling of the engine oil, the front tube of the frame was integrated into the oil circuit.Thus, when you change the oil, you also have to drain the engine oil from the front tube and bleed the oil system. If the oil system is not bled at all or bled insufficiently, the bearings of the engine will not get enough lubrication, which in turn may result in engine failure. The engine oil change is to be carried out when the engine is still warm. WARNING AN ENGINE HAVING BEEN RUN WARM, AND THE ENGINE OIL IN IT ARE VERY HOT DO NOT BURN YOURSELF. up to Modell 2001 from Modell 2002 on A A 1 - – Place the motorcycle on a horizontal surface. When working on a motorcycle with engine guard, remove the latter before commencing to change the engine oil. – Remove the two plugs 1 and 2, and drain oil into a container. ! PLUG A CAUTION ! MUST NOT BE REMOVED, THIS IS PART OF THE BY-PASS VALVE. 1 2 2 Changing the fine screen filter Replace the fine screen 3 filter when changing the engine oil. – Loosen the three bolts and remove the cover. – Undo the spin-on filter 3 with the corresponding special tool, twist it off manually and let the engine oil out of the front pipe of the frame. Art.-Nr. 3.206.006 -E 4 – Unscrew plug 4 at the lower end of the front pipe and drain oil (up to model 2000). 3 6 – Clean sealing surfaces on the front pipe 5, fill new fine screen filter with engine oil, and oil rubber gasket 6. Replace fine screen filter and screw it back in place, your bare hand will do. ! USE CAUTION USING ONLY ORIGINAL KTM FINE SCREEN FILTERS. RESULT IN DAMAGE TO THE ENGINE! Repair manual KTM LC4 5 ! ANOTHER FILTER BRAND CAN – From model 2001 onwards the drain plug 7 of the frame oil is located in the oil filter flange, draining is only possible after removing the oil filter. 7 – Clean all 3 plugs thoroughly with a fireproof solvent and compressed air, in order to remove the metal abrasion. – After all the oil has drained through, clean sealing areas and install plugs with gaskets. Tighten plug 1 with 30 Nm (23 ft.lb), plug 2 with 20 Nm and plug 4 with 10 Nm (up to model 2000). Drain plug of frame oil (model 2001 onwards) is to be mounted without a gasket and tightened to 10 Nm (7 lb.ft). 2-7D Changing the oil filter Replace the oil filter when changing the engine oil. – Press the foot brake pedal and place a screwdriver or similar between foot brake pedal and stopper roll so that the oil filter cover is more accessible. – Remove banjo bolt 1 and the three bolts 2. – Remove oil filter cover 3 and oil filter. – Clean filter housing, oil filter cover and sealing surfaces. Check oil duct in oil filter cover if clogged. 3 1 2 – Press the new O-ring 4 into the groove of the filter cover (if necessary fix with grease). Mount a new oil filter 5 on the connection piece of the oil filter cover an mount the whole unit. 1 3 NOTE: From model 2001 onwards the gasket 6 is mounted with a changed filter cover 3. If the new gasket 6 should be used on older engines, the filter cover must be flat regrinded or renewed (see Technical Info Nr. 0201/30/01). 4 2 6 5 – Mount three bolts and tighten with 5 Nm (4 ft.lb). – Mount banjo bolt with seal rings and tighten with 15 Nm (11 ft.lb). – Remove the oil dipstick at the clutch cover, pour in engine oil and replace the oil dipstick. Oil quantity (engine only) : 1.40 liter ! CAUTION ! IF THE ENGINE OIL HAS BEEN DRAINED FROM THE FRONT PIPE OF THE FRAME, YOU MUST BLEED THE OIL SYSTEM! – Remove the plug 7 next to the steering head and use a lubricating syringe 8 (see special tools) to fill the front pipe with approx. 0.6 l engine oil. Add oil until it begins to emerge at bore B. – Mount the plug, using a new seal ring. ! CAUTION ! DO NOT REV UP THE ENGINE IMMEDIATELY AFTER AN OIL CHANGE. KEEP IN MIND THAT IT TAKES SOME TIME UNTIL ALL LUBRICATING POINTS ARE PROPERLY PROVIDED WITH ENGINE OIL. 7 B – Allow the engine to run until warm. Then, turn off the engine, and place the motorbike on a flat, level surface in an upright position (center stand). Wait for 5 minutes. Unscrew and remove the oil dipstick, and wipe it clean with a cloth. – Screw the dipstick in all the way and remove it again. The oil level should be between the two marks on the oil dipstick, however, it must never rise above the MAX mark. Otherwise, engine oil would get into the air filter box by way of the engine venting system. Add engine oil, if necessary. – Finally, check oil system and engine for leaks. ! CAUTION ! – ONLY – – 8 USE HIGH-QUALITY OILS MEETING OR SURPASSING THE QUALITY REQUIREMENTS OF JASO T903 MA (FOR SPECIFICATIONS SEE CONTAINERS). INSUFFICIENT OIL OR POOR QUALITY OIL RESULTS IN PREMATURE WEAR OF THE ENGINE. YOU MAY USE EITHER MINERAL OILS OR SYNTHETIC OILS FULFILLING THE ABOVE CRITERIA. NOTE: Dispose of used oil properly ! Under no circumstances may used oil be disposed of in the sewage system or in the open countryside ! 1 liter oil contaminates 1.000.000 liter water ! 2-8D Oil circuit The oil pump 1 pumps the engine oil past the by-pass valve 2 through the oil filter 3. After the oil filter, an oil line branches off to a jet 4 which sprays engine oil onto the piston pin bearing and piston head. The second oil line takes the main flow of oil into the front pipe of the frame 5, where the engine oil is cooled down. Afterwards the engine oil runs through the fine screen filter 6, which filters out even the finest impurities. The cleaned engine oil is pumped through the oil line and the clutch cover into the crankshaft to the conrod bearing 7 and drips into the crankcase. An additional oil pump 8 sucks the engine oil out of the crankcase and pumps it through the oil line 9 to the gear wheels of the 4th and 5th gear. Via the gear wheels, the engine oil reaches the oil sump. The timing chain bk runs through the oil sump and transports the engine oil upwards to the cylinder head. Through the bore hole bl the oil reaches the camshaft bm and the valves. 11 12 5 Art.-Nr. 3.206.006 -E 10 4 Drain plug - frame oil up to Model 2000 7 6 8 3 Repair manual KTM LC4 1 2 Drain plug - frame oil Model 2001 onwards 9 2-9D Functional characteristics of the secondary air system (SLS) When the exhaust valve is open, the hot exhaust gases flow through the exhaust port 1 at a very high speed. As a consequence of the flow conditions in the exhaust port and due to the influence exerted by the entire exhaust system on the escaping gases, the pressure in the exhaust port drops temporarily (underpressure). During these cyclic underpressure phases, the secondary air valve 2 opens, thus adding oxygen of the air to the hot exhaust gases through pipe 3. At higher engine speeds, the secondary air valve interrupts the oxygen supply to prevent overheating of the catalytic converter. Additionally, the secondary air valve prevents the exhaust gases from flowing back into the air filter box 4. When the motorcycle is pushed (high underpressure in the intake port) the control valve (ASV) 5 interrupts the air flow into the exhaust port to prevent exhaust detonations. The control valve is controlled via a control pipe 6. This control pipe transmits the underpressure from the intake port 7 to the control valve. During normal operation (slight underpressure in the intake port), the control valve is open. The reaction between the oxygen of the air and the harmful components of the exhaust gases (CO - carbon monoxide, HC hydrocarbon) reduces the content of harmful substances by approximately 50%. The use of a catalytic converter, in combination with the SLS, allows an additional significant reduction of pollutant emissions. 6 3 5 4 2 1 7 2-10D Electronic Power Control System (EPC) Main components of the EPC system: – – – – – Constant-pressure carburetor Control device Solenoid valve 2 contact screws at the engine Micro-switch (at carburetor) Art.-Nr. 3.206.006 -E FUNCTIONAL CHARACTERISTICS: The EPC system is not activated during normal operation of the motorcycle. It is, however, activated as soon as the throttle is fully opened at a speed of 45 - 55 km/h while the second or third gear are engaged. The EPC control device opens the solenoid valve, directing an appropriate flow of fresh air onto the upper side of the slide membrane of the constant-pressure carburetor, thus reducing the opening speed of the slide. This mechanism significantly reduces the exhaust gas emissions of the vehicle. Repair manual KTM LC4 SOLENOID VALVE 2-11D SPECIAL TOOLS 39 6 26 11 12 8 64 1215 16 Silicone Liquid Gasket Silicone Flüssige Dichtung 1 23 4# 4 5# 5 5 27 7 150 10 3 49 14 70 19 9 2 17 8 22 8# 130 15 48 65 ThreeBond 20 35 18 2-12D Repair manual KTM LC4 Art.-Nr. 3.206.006 -E FIG. 1 2 3 4 4# 5 5# 6 7 8 8# 9 10 11 12 14 15 16 16 17 18 19 19 20 22 23 26 39 48 49 PART NO. 560.12.001.000 583.29.003.000 580.12.005.025 584.29.009.000 580.12.009.000 510.12.016.000 584.29.031.000 580.12.015.089 580.12.015.095 580.12.015.100 580.12.015.101 585.29.015.102 590.29.021.044 580.12.019.000 590.29.019.000 6.276.470 590.29.041.000 6.899.785 584.29.059.000 590.29.034.000 151.12.017.000 151.12.018.000 151.12.018.100 584.29.012.000 3090.98 584.29.037.040 584.29.037.043 580.30.080.000 510.12.012.000 546.29.027.000 580.29.026.007 583.29.039.000 584.29.048.000 503.29.050.000 DESCRIPTION Universal engine work stand Clutch holder Mounting sleeve for crankshaft seal ring Ø 25 mm Magneto extractor (Kokusan) Magneto extractor (SEM) Protection cover for crankshaft (SEM) Protection cover for crankshaft (Kokusan) Piston ringspanner Ø 89 mm Piston ringspanner Ø 95 mm Piston ringspanner Ø 100 mm Piston ringspanner Ø 101 mm Piston ringspanner Ø 102 mm Extractor for primary gear and clutch hub Valve mounting set Valve mounting set Valve spring-push insert Feeler gauge for valve clearance Loctite 243 blue 6 ml Loctite 648 red 20 ml Wrench for mixture regulating screw Gear puller Internal bearing puller 12 - 16 mm Internal bearing puller 18 - 23 mm Flywheel holding spanner (Kokusan) Seal (Three-Bond) Mounting tool inner ring NJ207 (all versions of LC4) Mounting tool inner ring NJ306 (LC4-E) Crankshaft locking bolt Chain sprocket holder Clutch rivetting tool Limit plug gauge Ø 7,05 mm Oil filter wrench Syringe for pipe oil Bleeding syringe for hydraulic clutch 2-13D 2 Checking the oil level of the hydraulic clutch 1 To check the oil level in the master cylinder of the clutch remove the cover. For this purpose, remove screws 1 and cover 2 together with the rubber boot 3 . The oil level in the horizontal-standing master cylinder should be 4 mm below the upper edge. If necessary, fill up with biodegradable hydraulic oil SAE 10 (f.ex. Motorex Kupplungs-Fluid 75). ! 3 CAUTION ! – KTM – USES BIODEGRADABLE HYDRAULIC OIL FOR THE HYDRAULIC CLUTCH CONTROL. NEVER MIX BIODEGRADABLE HYDRAULIC OILS WITH MINERAL OILS. ALWAYS USE BIODEGRADABLE HYDRAULIC OIL SAE 10 TO FILL UP THE MASTER CYLINDER. NEVER REFILL WITH MINERAL HYDRAULIC OIL OR BRAKE FLUID. Bleeding of the hydraulic clutch To bleed, the cover of the master cylinder of the clutch needs to be removed. For this purpose, remove screws 1 and take off cover 2 together with rubber bellows 3. At the slave cylinder of the clutch, remove the bleeder nipple 4. In its place, mount the bleeder syringe 5 which is filled with SAE 10 hydraulic oil. Refill oil until oil is discharged from the bore 6 of the master cylinder in a bubble-free state. Make sure that the oil does not overflow. The bleeder syringe can be purchased from your KTM dealer. 5 4 6 Having completed the bleeding procedure, you have to verify that the oil level in the master cylinder is correct. If necessary, fill up with biodegradable hydraulic oil SAE 10 (f.ex. Motorex Kupplungs-Fluid 75). CAUTION ! ! – KTM USES BIODEGRADABLE HYDRAULIC OIL FOR THE HYDRAULIC CLUTCH CONTROL. NEVER MIX BIODEGRADABLE HYDRAULIC OILS WITH MINERAL OILS. – ALWAYS USE BIODEGRADABLE HYDRAULIC OIL SAE 10 TO FILL UP THE MASTER CYLINDER. NEVER REFILL WITH MINERAL HYDRAULIC OIL OR BRAKE FLUID. 3-1D REMOVING AND REFITTING ENGINE INDEX Repair manual KTM LC4 Art.-Nr. 3.206.006 -E REMOVING THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2 REFITTING THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-4 3 3-2D Removing the engine – Thoroughly clean the entire motorcycle. – When working on a motorcycle with engine guard, remove the latter. – Jack the motorcycle up on a stable supporting device. – Remove the seat, the side covers as well as the tank and the spoilers. – Disconnect the negative pole of the battery. – Undo the 2 hose clamps 1 as well as hose clamp 2. Pull the carburetor backwards out of the intake flange and swing it aside. 2 1 Art.-Nr. 3.206.006 -E – Unhook the 4 springs 3 at the exhaust manifold. – Undo bolt 4. 3 4 Repair manual KTM LC4 – Undo bolt 5 and remove the exhaust manifold. 5 6 8 7 – Disconnect water hoses 6 and 7 from the water pump and let out the cooling liquid. – Remove the two bolts 8, disconnect and remove the fan. – Unhook the clutch cable and the decompression cable. – Disconnect the bleeder hose at the valve cover. 3-3D – Remove the two bolts 1 and take off the chain guard. – Remove the chain damping plate 6. – Remove the chain joint and take off the chain. 2 1 1 From model 2003 on: – Remove the 3 bolts 3 of the clutch slave cylinder and pull the clutch slave cylinder off the casing. 3 3 4 – Disconnect the bleeder hose 4. – Disconnect the positive cable 5 from the electric starter motor. 5 – Disconnect all electric plug and socket connections from the engine. – Remove the banjo bolt 6. 6 – Disconnect the water hose 7. 7 3-4D – Remove the jet screw 1. – Remove the left as well as the right engine retaining bracket 2. 1 2 – Remove bolt 3 as well as the swingarm pivot 4. – Then lift the engine out of the frame. 4 3 Installing the engine Art.-Nr. 3.206.006 -E NOTE: To install the engine reverse the procedure indicated above. – When working on a model with an engine guard keep in mind that opening A must be located on the right side and face the engine. Tightening torques: A Swingarm pivot: Engine mounting bolts M8: Engine mounting bolts M10: Banjo bolt (oil pipe on the frame): Jet screw (clutch cover): All other M6 bolts: All other M8 bolts: All other M10 bolts: 100 40 70 15 10 10 25 45 Nm Nm Nm Nm Nm Nm Nm Nm 74 30 50 11 7 7 19 33 ft.lb ft.lb ft.lb ft.lb ft.lb ft.lb ft.lb ft.lb NOTE: Use only high-quality antifreeze (e.g. Shell Advance Coolant) for the cooling system. The frame oil should always be changed after engine repair. ! CAUTION ! Repair manual KTM LC4 AFTER INSTALLING THE ENGINE CAREFULLY BLEED THE OIL SYSTEM (SEE OIL CHANGE INSTRUCTIONS). DO NOT REV THE ENGINE DURING THE BLEEDING PROCESS ! – The motorcycle can be tested as soon as the engine is running smoothly. After the test run check and, if necessary, correct all liquid levels. 4-1D DISASSEMBLING THE ENGINE Repair manual KTM LC4 Art.-Nr. 3.206.006 -E INDEX DRAIN ENGINE OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2 REMOVING THE ELECTRIC STARTER MOTOR . . . . . . . . . . . . . . . . . . . . .4-2 REMOVING THE CLUTCH RELEASE LEVER AND THE OIL HOSES . . . . . . .4-3 REMOVING THE OIL FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-3 REMOVING THE EPC WIRING HARNESS . . . . . . . . . . . . . . . . . . . . . . . . . .4-3 REMOVING THE IGNITION (KOKUSAN 4K-2) . . . . . . . . . . . . . . . . . . . . . .4-3 REMOVING THE IGNITION (SEM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-5 REMOVING THE IGNITION (KOKUSAN 4K-3) . . . . . . . . . . . . . . . . . . . . . .4-5 REMOVING THE ELECTRIC STARTER DRIVE . . . . . . . . . . . . . . . . . . . . . . .4-6 REMOVING THE CYLINDER HEAD TOP SECTION . . . . . . . . . . . . . . . . . . .4-7 BLOCKING THE CRANKSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-8 REMOVING THE CAMSHAFT AND THE AUTOMATIC TENSIONER . . . . . .4-8 REMOVING CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-10 REMOVING CYLINDER AND PISTON . . . . . . . . . . . . . . . . . . . . . . . . . . .4-10 REMOVING ENGINE SPROCKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-11 REMOVING CLUTCH AND PRIMARY DRIVE . . . . . . . . . . . . . . . . . . . . . .4-11 REMOVING THE OIL PUMPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-13 REMOVING THE TIMING CHAIN AND THE TIMING GEAR . . . . . . . . . . .4-14 REMOVING THE CLUTCH RELEASE SHAFT . . . . . . . . . . . . . . . . . . . . . . .4-14 PARTING OF ENGINE HOUSING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-15 REMOVING THE SHIFT MECHANISM . . . . . . . . . . . . . . . . . . . . . . . . . . .4-15 REMOVING THE TRANSMISSION SHAFTS . . . . . . . . . . . . . . . . . . . . . . .4-17 REMOVING THE KICKSTARTER SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . .4-17 4 4-2D – Fit engine to engine work stand. – Remove bolt 1 together with the washers. Then remove the shift lever together with the V-seal ring behind. – Remove bolt 2 together with the washer. Then remove the kickstarter. 1 2 Art.-Nr. 3.206.006 -E – Remove spark plug up to model 2001 from modell 2002 on Drain engine oil – Remove oil drain plug 3 and magnetic plug 4 and drain oil. Repair manual KTM LC4 3 4 3 4 Removing the electric starter motor 5 – Undo 2 bolts 5 and remove the electric starter motor from the flange. 4-3D Removing the clutch release lever and the oil hoses – Undo bolt 1 and remove the clutch release lever. 1 – Remove the two banjo bolts 2 together with the seal rings and remove both oil hoses. 2 2 Removing the oil filter – Remove all three bolts 3 and take off the oil filter cover together with the O-ring or gasket. – Take the oil filter out of the engine housing. 3 Removing the EPC wiring harness 4 – Undo the 3 bolts 4 and remove the EPC wiring harness. 4 Removing the ignition (Kokusan 4K-2) – Undo 4 bolts and remove the ignition cover with the stator incl. gasket. 4-4D – Undo 6 bolts and remove starter flange incl. gasket. – Insert the holding spanner 2 into the 2 bores of the flywheel. – Hold the flywheel and remove the hexagon nut (LH thread). – Remove the disc. ! 2 CAUTION ! TO AVOID DISTORTION OF THE CRANK WEB, NEVER MOUNT THE CRANKSHAFT LOCKING BOLT TO STEADY THE FLYWHEEL. Art.-Nr. 3.206.006 -E – Put the protection cover 1 onto the crankshaft and mount the flywheel extractor. 1 – Pull off the flywheel and take the woodruff key out of the crankshaft. ! CAUTION ! Repair manual KTM LC4 NEVER USE A HAMMER OR ANY OTHER TOOL ON THE FLYWHEEL TO AVOID LOOSENING OF THE MAGNETS. 4-5D Removing the ignition (SEM) – Undo the 4 bolts and remove ignition cover and O-ring. – Use the crankshaft locking bolt to block the crankshaft. – – – – Unscrew collar nut (LH thread) and remove spring disc. Fit extractor and pull off flywheel. Use protective sleeve. Remove woodruff key from the crankshaft. Twist the crankshaft locking bolt out until the crankshaft is no longer blocked. ! CAUTION ! NEVER USE A HAMMER OR ANY OTHER TOOL ON THE FLYWHEEL TO AVOID LOOSENING OF THE MAGNETS. Removing the ignition (Kokusan 4K-3) – Undo the 4 bolts and take off the ignition cover together with the O-ring. – Use the crankshaft locking bolt to block the crankshaft. – Undo the collar nut (LH thread) and remove the spring washer. – Mount the extractor and pull off the flywheel. – Take the woodruff key out of the crankshaft. – Finally, twist out the crankshaft locking bolt until the crankshaft is no longer blocked. ! NEVER CAUTION ! USE A HAMMER OR SIMILAR TOOL ON THE FLYWHEEL TO PREVENT LOOSENING OF THE MAGNETS. 4-6D 1 Removing the electric starter drive 2 – Pull the reduction gear 1 off the bearing bolt. – Remove both needle bearings 2 and pull the bearing bolt 3 out of the engine housing. 3 – Remove the freewheel gear 4 and the needle bearing 5. 5 Repair manual KTM LC4 Art.-Nr. 3.206.006 -E 4 4-7D Removing the cylinder head top section – Unscrew plug 1 with gasket and remove pressure spring from automatic tensioner. 1 – Undo the 4 hose clamps and remove both hoses (2 and 3). 2 3 – Remove all 6 bolts 4 together with the seal rings and take off both valve covers together with the gaskets. 4 – Remove the hexagon nut 5 and take off the retaining bracket of the solenoid valve 6. NOTE: A retaining bracket is only used in engines with EPC. 6 5 – Remove all 11 bolts. Then remove the cylinder head top section. ! WHEN CAUTION ! REMOVING CYLINDER HEAD TOP SECTION DO NOT CHOCK IT. DAMAGE THE HOUSING OF THE WATER PUMP. THIS WOULD NOTE: The control valve of SLS models can be removed after undoing the bolts of the cylinder head top section. 4-8D – Pull water pump upward and simultaneously turn crankshaft. NOTE: When groove A in the HH bolt is vertical, the water pump can be pulled upward and taken out of the cylinder head without the application of force. A Blocking the crankshaft – Turn the piston to position TDC (mark B must coincide with the plane surface of the cylinder head). B – Undo the crankshaft locking bolt 1. – Remove the copper disc 2. 2 Art.-Nr. 3.206.006 -E 1 NOTE: Same engines are equipped with a normal bolt M8x16 and a copper washer 8x12x1 instead of the crankshaft locking bolt M8 and a copper washer 8x14x3. In this case the special tool 580.30.080.000 must be used. – Reinsert crankshaft locking bolt by hand. – If the bolt does not slide smoothly into its bore, slightly move the camshaft gear (if cylinder head top section is mounted turn the flywheel) back and forth until the crankshaft locking bolt engages in its bore. – Tighten crankshaft locking bolt with 20 Nm. ! UNDER CAUTION bolt NO CIRCUMSTANCES APPLY FORCE TO AS THIS WILL DAMAGE THE CRANKSHAFT. ! IN CRANKSHAFT LOCKING BOLT Removing the camshaft and the automatic tensioner – Remove the driving bolt 3 together with the two washers. Repair manual KTM LC4 3 6 4 5 – Remove the two bolt 4 and take off the automatic tensioner 5 and the clamp 6. 4-9D – Using a screwdriver, lever circlip 1 out of the groove. 1 – Tilt camshaft and remove needle bushing 2. 2 – While tilted, pull camshaft from camshaft gear and remove together with grooved ball bearing and circlip. – Take the camshaft gear out of the timing chain as indicated in the illustration. 4-10D 1 Removing cylinder head – Unscrew chain guide bolt 1 incl. gasket, bolts 2 and collar nuts 3. 3 2 – Unscrew the 4 collar bolts 4 and detach cylinder head with gasket. 4 Removing cylinder and piston Art.-Nr. 3.206.006 -E – Unscrew the 4 collar nuts at the cylinder base 5. – Remove cylinder and cylinder base gasket. 5 Repair manual KTM LC4 6 – When working on an engine with a microfilter, remove the AH bolt 6 before taking off the cylinder. – Disconnect the oil hose at the clutch cover and remove the microfilter together with the holder. 4-11D – Remove two wire circlips and press piston pin out of piston. – Remove piston. Removing engine sprocket – Remove collar bolt 1 and spring washer. – Remove the sprocket from the counteshaft. – Remove the distance bushing from the countershaft. 1 NOTE: If the gear-box and the clutch of the engine are in good condition, throw it into gear in order to block the take-off shaft (frictional connection to the blocked crankshaft is present). If the takeoff shaft cannot be blocked as described above, a chain sprocket holder must be applied for the removal of the chain sprocket nut. Removing clutch and primary drive – Remove the 11 bolts and detach clutch cover with gasket. – Unscrew the bolts 3 of the clutch crosswise to prevent the clutch discs from jamming when the springs are relieved of tension. – Remove bolts, spring retainer and springs. – Remove pressure cap with push rod. 3 – Remove the disc package and take the O-ring 2 also off the inner clutch hub. 2 4-12D – Release the lock washer of the inner clutch hub. – Put the clutch holder 1 onto the inner clutch hub and undo the hexagon nut (see illustration). – Remove the clutch holder. – Take the hexagon nut, the lock washer and the inner clutch hub off the main shaft. 1 – Try to turn the outer clutch hub in both directions to check the absorbing elements. Dead travel in either direction is inadmissible. Art.-Nr. 3.206.006 -E – Take the outer clutch hub and the needle bearing 2 off the main shaft. 2 – Remove the kickstarter intermediate gear 3. Repair manual KTM LC4 3 – Unscrew hexagon nut of primary gear wheel and detach spring washer from the crankshaft. – Fit extractor for primary gear and pull off primary gear. 4-13D – Remove the balancer shaft from the bearing by hand. Removing the oil pumps 3 1 NOTE: The following procedure must always be performed on both oil pumps. – Remove the locking washer 1. – Remove stop disc 2 and the oil pump gear 3. 2 – Remove the needle roll 4 and stop disc 5. 4 5 – Twist out the 6 bolts 6 and remove the oil pumps from the housing. NOTE: For better access to bolt 7 remove bolts 8 and take off the retaining bracket. 7 8 6 4-14D 2 1 Removing the timing chain and the timing gear – Remove allan head bolt 1 and remove timing chain guide from the casing. – Unscrew flat-head screw 2 and remove timing chain tensioner. – Unscrew allan head bolt 3 and remove timing chain securing guide. – Insert timing chain into the clutch compartment of the engine housing and disengage from timing gear. 3 – Remove the primary gear woodruff key 4 from the crankshaft. – Withdraw the timing pinion from crankshaft with a 2-jaw puller. – Take the woodruff key of the timing gear out of the crankshaft. 4 Removing the clutch release shaft Art.-Nr. 3.206.006 -E – Remove bolt(s) 5 and take off the retaining bracket 6. 5 6 Repair manual KTM LC4 7 8 – Pull the clutch release shaft 7 out of the housing. – Remove the grooved ring 8. 4-15D Parting of engine housing – – – – Loosen the crankshaft locking bolt. Tip ignition side upwards and remove all the housing bolts. Release engine mount on engine repair stand. Lift right hand housing half with suitable tools bearing on the bosses provided, or part with a few light plastic mallet blows against the counter shaft. ! CAUTION ! LEVERING APART WITH A SCREW-DRIVER OR SIMILAR TOOL MUST BE AVOIDED, SINCE THE SEALING SURFACES ARE EASILY DAMAGED. – Remove housing-half and gasket. 1 – Take the stop disc 1 off the main shaft (can stick to the inside of the housing). – Take the O-ring 2 off the countershaft. – Remove the crankshaft from the bearing by hand. 2 – Take the inner ring 3 of the roller bearing and the O-ring below 4 off the countershaft. 3 4 Removing the shift mechanism – Push back slide plate 5 and pull shift shaft out of the kickstarter shaft. – Remove allan head bolt 6 and detach locking piece. 6 5 4-16D – Remove the 3 bolts 1 and detach the shift mechanism support 2. 2 1 1 3 4 – Pull out the shift rails 3 and swing the shift forks aside, taking care of the shift rolls 6 on the driving pins of the shift forks. – Pull the shift roller 4 out of the bearing seat. 3 5 Art.-Nr. 3.206.006 -E NOTE: Although the counter shaft shift forks are identical they should be refitted in the same position as before if reused. Therefore mark accordingly upon removal. 6 Repair manual KTM LC4 – Take the shift forks 5 together with the shift rolls 6 out of the engine housing. 4-17D Removing the transmission shafts – Pull both transmission shafts out of the bearing seats. – Take the 3rd gear/sliding gear and the 1st gear/idler gear out of the engine housing together with the needle bearing and the stop disc. NOTE: A roller bearing was installed in the 660 SMC model, thus a stop disc is unnecessary. Removing the kickstarter shaft – Put kickstarter onto kickstarter shaft and hold in this position. – Unscrew stop bolt 1 and relieve starter spring tension by releasing the kickstarter. 1 – Remove kickstarter shaft assembly from housing. – Take the starter gear out of the housing bag together with the needle bearing and the stop discs. – Clean all parts and check for wear, replace if necessary. NOTE: When an engine is completely overhauled it is recommended that all gaskets, shaft seal rings, O-rings and, possibly, all bearings are renewed. 5-1D SERVICING ON INDIVIDUAL COMPONENTS Repair manual KTM LC4 Art.-Nr. 3.206.006 -E INDEX WORKING ON THE RIGHT HOUSING HALF . . . . . . . . . . . . . . . . . . . . . . .5-3 WORKING ON THE LEFT HOUSING HALF . . . . . . . . . . . . . . . . . . . . . . . .5-5 CRANKSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-6 MEASURING AND ADJUSTING OF CRANKSHAFT AXIAL PLAY . . . . . . . . .5-7 CHECKING THE PISTON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-7 MOUNTING INSTRUCTIONS FOR PISTON RINGS . . . . . . . . . . . . . . . . . . .5-8 PISTON RING END GAP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-8 MEASURING PISTON AND CYLINDER, DETERMINING THE PISTON FITTING CLEARANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-8 CYLINDER – NIKASIL COATING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-9 RECOATED CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-9 DISASSEMBLING THE CYLINDER HEAD AND CHECKING THE COMPONENTS FOR WEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-10 DISASSEMBLING THE CYLINDER HEAD TOP SECTION AND CHECKING COMPONENTS FOR WEAR . . . . . . . . . . . . . . . . . . . . . . . . .5-11 PRE-ASSEMBLING THE CYLINDER HEAD TOP SECTION . . . . . . . . . . . . .5-11 CHECKING THE COMPONENTS OF THE TIMING MECHANISM FOR WEAR . . .5-12 DISASSEMBLING THE CAMSHAFT AND CHECKING THE COMPONENTS FOR WEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-12 PRE-ASSEMBLING THE CAMSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-12 AUTOMATIC TENSIONER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-13 PREASSEMBLY OF AUTOMATIC TENSIONER . . . . . . . . . . . . . . . . . . . . .5-13 DISASSEMBLING THE OIL PUMPS AND CHECKING THE COMPONENTS FOR WEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-13 OIL LINES (SX, SXC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-14 OIL LINES (SC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-14 OIL LINES (660 SMC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-15 OIL LINES (MODELS WITH FRAME OIL) . . . . . . . . . . . . . . . . . . . . . . . . .5-15 CHECKING THE KICKSTARTER COMPONENTS FOR WEAR . . . . . . . . . . .5-16 PREASSEMBLY OF KICKSTARTER SHAFT . . . . . . . . . . . . . . . . . . . . . . . . .5-16 CLUTCH COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-16 REPLACING ABSORBING ELEMENTS OF THE OUTER CLUTCH HUB . . . .5-16 5 5-2D INDEX CHECKING THE CLUTCH COMPONENTS FOR WEAR . . . . . . . . . CHECKING THE SHIFT MECHANISM COMPONENTS FOR WEAR . PREASSEMBLY OF SHIFT SHAFT . . . . . . . . . . . . . . . . . . . . . . . . SHIFT MECHANISM SUPPORT . . . . . . . . . . . . . . . . . . . . . . . . . BALANCER SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DISASSEMBLING AND REASSEMBLING THE WATER PUMP . . . . . IMPORTANT NOTE REGARDS WORKING ON TRANSMISSION . . ASSEMBLING THE MAIN SHAFT . . . . . . . . . . . . . . . . . . . . . . . . ASSEMBLING THE COUNTER SHAFT . . . . . . . . . . . . . . . . . . . . . REMOVING THE INTERMEDIATE GEAR . . . . . . . . . . . . . . . . . . . CHECKING THE FREEWHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . REPLACING THE FREEWHEEL HUB . . . . . . . . . . . . . . . . . . . . . . ELECTRIC STARTER MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . IGNITION (KOKUSAN 4K-2) . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE STATOR AND THE PULSE GENERATOR (KOKUSAN 4K-2) REPLACING THE STATOR (KOKUSAN 4K-2) IGNITION (SEM) . . . . . . . . . . . . . . . . . . . CHECKING THE STATOR (SEM) . . . . . . . . . REPLACING THE STATOR (SEM) . . . . . . . . CHECKING THE STATOR (KOKUSAN 4K-3) REPLACING THE STATOR (KOKUSAN 4K-3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-17 .5-18 .5-18 .5-19 .5-19 .5-19 .5-20 .5-20 .5-21 .5-22 .5-22 .5-22 .5-22 .5-23 . . . . . . . . . . . . . . .5-23 .5-23 .5-24 .5-24 .5-24 .5-25 .5-25 IMPORTANT NOTE REGARDS WORKING ON ENGINE HOUSING Read through the following section before commencing work. Then determine the assembly sequence so that the engine housing halves only need to be heated up once before replacing the bearings. Having first removed the dowels, in order to expel the bearings or remove them with light mallet blows, the housing halves must be placed on a suitably large plane surface, supporting the whole of the sealing surface without damaging it. A wooden panel is best used as a base. Bearings or shaft seal rings should not be hammered into their seats. If no suitable press is available, use a suitable mandrel and hammer them in with great care. Cold bearings will practically drop into their seats at an engine housing temperature of approx. 150° C. After cooling, should the bearings fail to lock in the bore, they are bound to rotate after warming. In that event the housing must be replaced. 5-3D Working on the right housing half Remove shaft seal rings and heat housing half to approx. 150° C by means of a hot-plate. Roller bearing of crankshaft 1 Proceed as for left housing half. 4 5 3 3 Cylinder roller bearing of counter shaft 2 Remove shaft seal ring. Press old bearing inwards. Press in new bearing from inside as far as stop. Oil ducts 3 Use compressed air to clean all oil ducts. Ensure that the oil ducts are not clogged. Counter shaft seal ring 4 Press in new shaft seal ring from outside until flush. Crankshaft seal ring 8 Press in new shaft seal ring from outside until flush. NOTE: Engine with an electric starter have a stop disk instead of the shaft seal ring 5. Do not remove this disk. 6 Art.-Nr. 3.206.006 -E 1 2 8 Repair manual KTM LC4 Needle bearing of main shaft 6 Pull old bearing from bearing seat using bearing extracto and insert. In order to apply the bearing extractor in an vertical position, a steel plate (see special tools) must be laid on the sealing area of the housing. The bearing extractor jaws should fit as close as possible up to the housing walls. Then press in new bearing from inside until flush. 6 Oil nozzle 7 For the cleaning of the oil nozzle and the oil duct simply blow it through with compressed air from the nozzle side. If the oil nozzle is disassembled, secure it with Loctite 243 when mounting again. Then check the lubrication bore A of the crankshaft roller bearing for free passage. 7 After the case half has cooled down, check bearings for secure fit. A 5-4D Needle bushes of the clutch disengagement – Pull out the needle bushes of the clutch disengagement with a gear puller and insert from the housing half. – Oil the needle bushes. – Press the first needle bush A to stop. – Press the second needle bush B so that it is flush. B A 5-5D Working on the left half of the housing 5 4 1 Remove shaft seal rings and heat housing half to approx. 150° C by means of a hot-plate. Needle bearing of counter shaft 1 Press in new needle bearing from inside until flush. Shaft seal ring of kickstarter shaft 2 Press in new shaft seal ring from outside with sealing lip facing inwards until flush. Grooved ball bearing of the balancer shaft 3. Use an extractor and insert to remove the grooved ball bearing from the housing half. 2 3 6 Shaft seal ring of crankshaft 4 Press in new shaft seal ring from outside with sealing lip facing inwards until flush. 6 Retaining plate for main shaft grooved ball bearing 5 If the retaining plate has been removed, use Loctite 243 for the two countersunk bolts during assembly. Oil ducts 6 Use compressed air to clean all oil ducts. Ensure that the oil ducts are not clogged. 8 7 9 Roller bearing of crankshaft 7 From outside press crankshaft roller bearing inwards using a suitable mandrel. Press in new roller bearing from inside up to the stop. Art.-Nr. 3.206.006 -E Grooved ball bearing of main shaft 8 Press in new grooved ball bearing from inside up to the stop. ! CAUTION ! DO NOT USE FORCE WHEN PRESSING THE GROOVED BALL BEARING AGAINST THE RETAINING PLATE 5 TO AVOID A BENDING OF THE PLATE, WHICH WOULD RESULT IN EXCESSIVE AXIAL PLAY OF THE MAIN SHAFT. Needle bearing of kickstarter shaft 9 Press in new needle bearing from inside until flush. 3 Bypass valve Test valve piston, tight fit and pressure spring for damage. Minimum length of the pressure spring bk: 23,5 mm Repair manual KTM LC4 10 NOTE: The opening pressure of the bypass valve is reduced when the length of the pressure spring decreases below 23,5 mm. This reduces the oil pressure and causes engine damage. Ensure that neither the lubrication bore of the roller bearing A nor the oil ducts of the oil pumps are clogged. – After the housing half has cooled down, check bearings for tight fit. – Finally, insert both dowels so that the dowel with internal diameter 15.4 mm is mounted at the rear (swingarm pivot). A 5-6D B C Crankshaft If the conrod bearing is replaced, take care to properly position the crankpin. The bores of the crank web B and crank pin C must coincide. ! CAUTION ! IF THE CRANK PIN IS PRESSED IN THE WRONG POSITION, THE CONROD BEARING IS SUPPLIED INSUFFICIENTLY OR NOT AT ALL WITH ENGINE OIL, WHICH RESULTS IN BEARING DAMAGE. If the crankshaft is continued to be used, check crankshaft journals for run out. Place crankshaft on a roller block or a similar device and check the outer end of the journals for run out with a dial gauge. run out of crankshaft journals: max. 0.04 mm (0.0016 in) The radial clearance and axial clearance on the conrod bearing must be checked. radial clearance: max. 0.05 mm (0.0019 in) axial clearance: max. 1.00 mm (0.04 in) – If the crankshaft roller bearings are replaced, the inner rings on the crankshaft should also be changed. – Heat special tool on a heating pad up to approx. 150°C and slip it on the inner ring immediately. Press the special tool together tightly to obtain a good heat transfer and pull the inner ring off the crankshaft. – To mount the new inner ring, heat the special tool again to approx. 150°C, engage the inner ring and slip it on the crankshaft journal immediately. – In order to safely press on new rings, a middle panel should be inserted between the crankshaft webs. This panel should be big enough to be supported on both sides, so that the crankshaft lies free and accessible. NOTE: Because LC4-E models have different diameters of inner crankshaft bearing rings, it is necessary to have both special tools (584.29.037.040 and 584.29.037.043). ! CAUTION ! NEVER CLAMP THE CRANKSHAFT WITH A CRANKSHAFT JOURNAL OR WEB IN THE VICE, AND NEVER TRY TO KNOCK THE INNER RING FREE. THE CRANKSHAFT WEBS MAY BE COMPRESSED THEREBY MAKING THE CRANKSHAFT UNUSEABLE. 5-7D Measuring and adjusting of crankshaft axial clearance – Should the crankshaft, engine housing, or a roller bearing be replaced, the axial clearance of the crankshaft should also be checked. – The housing should be laid inside upwards, then measure the distance from the sealing area to the inner rings of the roller bearings. Note the readings and then add on 0.3 mm to allow for gasket thickness. – Measure the crankshaft at touching points and then subtract the measured value from the housing dimensions. This figure will be the axial play of the crankshaft, which should be 0.03- 0.12 mm (0.0010.005 in). EXAMPLE: Left-hand housing half Right-hand housing half Gasket Total housing dimension Crankshaft dimension Axial play present + + = – = 33.0 32.8 0.3 66.1 65.8 0.3 mm mm mm mm mm mm 1.300 1.290 0.012 2.602 2.590 0.012 ( ( ( ( ( ( in) in) in) in) in) in) The compensating washers should be equally distributed between the two sides of the crankshaft. In our example, one compensation washer (≠ 0.1 mm / 0.004 in.) must be mounted on either side. Art.-Nr. 3.206.006 -E Checking the piston – Replace the piston in the case of excessive oil consumption or grooves in the piston skirt. – If reinstalling the old piston perform the following steps: 1. Piston bearing surface - check for damage 2. Piston ring grooves - the piston rings must move easily in the groove. Old piston rings or sandpaper (400 grit) may be used to clean the piston ring grooves. 3. Piston rings - check for damage and end gap (see below). 4. The piston pin must move freely in the piston when mounted. If the piston pin changed its color badly or shows running traces, it must be replaced. Insert piston pin also into the conrod and check for clearance. Maximum clearance in the conrod eye 0.08 mm (0.003 in). Repair manual KTM LC4 NOTE: When in place, the piston pin may not have any play. It must be possible to shift it with slight counterpressure. 5-8D Mounting instructions for piston rings – Insert the oil scraper ring in the lower ring groove. Side of ring marked facing piston head. – Mount compression ring (tapered compression piston ring) in middle ring groove. Side of ring marked facing piston head. – Insert the compression ring (rectangular ring) in the upper piston ring groove (the surface marked must be on top). ELKO Ø 89 mm ELKO Ø 95 mm ELKO Ø 101 mm ARIAS Ø 101 mm O O O N 100 Tapered ring TOP TOP TOP N 101 Oil scraper ring ELKO TOP TOP ––– Compression ring Piston ring end gap – Insert pisto ring into the cylinder and adjust. Piston ring must be approx. 10 mm (1/2 inch) from top of cylinder. – The end gap B can now be checked which a feeler gauge. Compression rings: max. 0.60 mm (0.023 in) Oil scraper ring: max. 0.80 mm (0.03 in) If the end gap is greater check piston and cylinder for wear. If piston and cylinder wear are within the permitted tolerance limits, replace the piston ring. Measuring piston and cylinder, determining the piston fitting clearance – In order to determine the wear of the cylinder, measure the cylinder center of the running area with a micrometer. – Measure the diameter of the x-axis and the y-axis in order to check for oval wear, if any. x y – The piston is measured on the piston skirt across to the piston pin as shown in the illustration. – The cylinder diameter minus the piston diameter yields the piston assembly clearance. Piston assembly clearence: see Technical Specification 5-9D Cylinder – nikasil coating Nikasil is the brand name for a cylinder coating process, developed by the piston manufacturer Mahle. The name is derived from the two materials used in this process - a nickel layer into which the particularly hard silicon carbide is embedded. The main advantages of the Nikasil coating are excellent heat dissipation and thus better power output, low wear and low weight of the cylinder. The worn coating can be regenerated at low cost provided that the running surface of cylinder is flawless. Recoated cylinder Repair manual KTM LC4 Art.-Nr. 3.206.006 -E If the Nikasil coating of your cylinder is worn but undamaged, you may obtain a recoated cylinder at your KTM dealer (new Nikasil coating on used cylinder). It may be that your spare cylinder shows color changes on the exterior side. 5-10D Disassembling the cylinder head and checking the components for wear Three-Bond Dichtmasse Three-Bond Gasket – Mount cylinder head in vice using the studs. Do not allow it to rest on sealing surface. – Mark valves and remove using special tool (see illustration). – Clean all parts. Sealing area Check spark plug threads and valve seats for damage or cracks. Check the sealing area to the cylinder for distortions with a straightedge and a feeler gauge. Distortion limit 0.10 mm (0.004 in). Valve guides The valve guides are checked with a limit plug gauge 1 (Ø 7.05 mm). If the limit plug gauge can be easily inserted into the valve guide, the guide must be replaced in a specialized workshop. Valve seats The valve seats must not be pocketed. Seat sealing width: intake max. 1.5 mm (0.059 in); exhaust max. 2.0 mm (0.079 in). Grind valves if necessary. 1 Valves Check valve heads for wear and run out. Max. run-out on valve heads 0.03 mm (0.001 in). Valve seats should not be pocketed. The sealing area must be located in the center of the valve seat. The valve stem is hard-chrome plated. Experience shows that wear appears primarily on the valve guide. Valve springs Only visual check for breakage or wear is necessary. Valve stem seals Always renew valve stem seals when the valves are removed. Intake flange Check flange surface for distortion, scrape on glas plate if necessary. 5-11D Disassembling the cylinder head top section and checking the components for wear – Simply pull the rocker arm axles 1 out of the cylinder head top section. Then take both rocker arms 2 together with thrust washers 3 and bn out of the cylinder head top section. Undo bolt 4 and remove the following components: 15 1 15 12 3 – Press the decompression shaft bk inwards and take it out of the cylinder head top section together with the washers bl. – Clean all components. 1 2 Rocker arm shafts 1 The rocker arm shafts must be free of grooves and should turn easily within the rocker arms 2. 3 14 2 12 13 Washer 5 Decompression shaft lever 6 Covering disc 7 O-ring 8 Decompression lever spring 9 14 13 10 Rocker arm rollers bm The rocker arm rollers must move smoothly. Rocker arm rollers must be removed in the case of radial clearance. Adjusting screws bo The contact surfaces of the adjusting screws must be plane. Art.-Nr. 3.206.006 -E Decompression shaft bk Check for smooth operation and clearance in the bearing bore. 6 4 5 7 8 9 11 10 Pre-assembling the cylinder head top section Repair manual KTM LC4 – Insert decompression shaft bk with compensation washers bl into the top section. – Mount the new O-ring 8, the decompression lever spring 9 and the cover disc 7 in such a way that the O-ring fits into the recess of the cover disc. – Mount the decompression shaft lever 6. – Apply Loctite 243 to the thread of bolt 4 and mount the bolt together with washer 5. – Hook the decompression lever spring onto the decompression shaft lever. ! CAUTION ! THE DECOMPRESSION SHAFT MUST EXHIBIT NO AXIAL PLAY WHEN THE ALLAN HEAD BOLT 4 IS TIGHTENED. TO ENSURE THAT THE O-RING 8 fORMS A SEAL, IT MUST BE SLIGHTLY PRESSED AGAINST THE TOP SECTION BY THE COVER DISC 7. HOWEVER, THE PRESSURE ON THE O-RING MUST NOT BE EXCESSIVELY HIGH AS THE ADJUST OUT WITH DECOMPRESSION SHAFT WILL BECOME SLUGGISH. COMPENSATION WASHERS bl IF NECESSARY. 13 NOTE: Discs bl are available 0.15 mm, 0.30 mm and 0.50 mm thick. – Mount new O-rings bp on rocker arm shafts 1. – Mount rocker arms 2, thrust washers 3 and rocker arm shafts 1. – On the side of the water pump one thrust washer bn ≠ 1.0 mm (0.04 in) must be mounted. – The axial play on the opposite side is roughly equalized with thrust washers 3 ≠ 1.0 (0.04 in) and ≠ 0.5 mm (0.02 in). The axial clearance of the rocker arm axles must be 0.20 - 0.30 mm. 5-12D Checking the components of the timing mechanism for wear Timing chain guide 1 Check for signs of wear. 8 Timing chain tensioner 2 Check for signs of wear. 6 5 Timing chain 3 Check rollers for smooth operation and signs of wear. LOCTITE 243 2 3 1 Timing gear 4 Check teeth for signs of wear. Camshaft gear 5 Check teeth for signs of wear. Grooved ball bearing 6 Check clearance. LOCTITE 243 Safety device 7 Check for signs of wear. 4 LOCTITE 243 Camshaft 8 Check pivot points and running surfaces for signs of wear. LOCTITE 243 7 11 9 Disassembling the camshaft and checking the components for wear – Remove both the stepped ring bo and the circlip bp. Carefully remove the decompression cam bm. Keep a watch on the spring 9. Supporting pin bk Check for signs of wear. Guide pin bl Check for signs of wear. 10 Decompression cam bm Check the contact surfaces towards the supporting pin for signs of wear. Spring 9 Check length (minimum length: 7.0 mm/0.275 in). B Camshaft bn Check for signs of wear at pivot point A. Minimum diameter of the pivot point 19.97 mm. Preassembling the camshaft 9 A 13 – Place spring 9 in the bore, compress and slide decompression cam bm over it. – Mount circlip bp with the sharp side towards the decompression cam. – Position the open side B of the circlip between the open spaces of the decompression cam. – Slide the step ring bo with open spaces over the lock washer. 12 15 14 5-13D Automatic tensioner – Check ratcheting pawl 1 for smooth operation and wear. – Check thrust bolt 2 for wear at teeth. 1 2 Preassembly of automatic tensioner – Insert thrust bolt into tensioner housing and engage ratcheting pawl into first notch (see illustration). 1 ! CAUTION ! IF THE RATCHETING PAWL IS NOT ENGAGED INTO THE FIRST NOTCH THIS WILL CAUSE EXCESSIVE TENSION OF THE CHAIN. 2 Disassembling the oil pumps and checking the components for wear Art.-Nr. 3.206.006 -E 4 NOTE: The two oil pumps are similar in design but work at different speeds. Disassemble and check the oil pumps separately to avoid mixing up of components. 3 – Remove screw 3 and take off the oil pump cover 4. – Pull the oil pump shaft 5 out of the oil pump housing together with the bearing needle. – Take the inner rotor 6 and the outer rotor 7 out of the oil pump housing. – Clean all components and check for signs of wear. Repair manual KTM LC4 7 5 – When reassembling the unit insert the inner rotor and the outer rotor into the oil pump housing, making sure that the point faces the inside. – Mount oil pump shaft and bearing needle 6 – Now perform the following measurements to determine the degree of wear: Outer rotor - oil pump housing: max. 0.20 mm Outer rotor - inner rotor: max. 0.20 mm – Fill the oil pump housing with oil and mount the oil pump cover. – Apply Loctite 243 to the thread of screw 3 and mount the screw. ! FILL CAUTION OIL PUMPS WITH OIL BEFORE PREASSEMBLING. ! 5-14D Oil lines (SX, SXC) – Check oil lines and banjo bolts for damage and clear passage. – When repairing the engine, the microfilter 1 and the oil filter 2 must be replaced. 2 1 150 LOCTITE 243 LOCTITE 243 Oil lines (SC) – Check oil lines and banjo bolts for damage and clear passage. – When repairing the engine, the microfilter 3 and the oil filter 4 must be replaced. 4 3 150 LOCTITE 243 LOCTITE 243 5-15D Oil lines (660 SMC) – Check oil lines and banjo bolts for damage and clear passage. – When repairing the engine, the microfilter 1 and the oil filter 2 must be replaced. 2 1 4 C L LOCTITE 243 LOCTITE 243 Oil lines (Models with frame oil) Art.-Nr. 3.206.006 -E – Check oil lines and banjo bolts for damage and clear passage. – When repairing the engine, the fine filter 3 and the oil filter 4 must be replaced. 4 150 3 Repair manual KTM LC4 LOCTITE 243 LOCTITE 243 5-16D Checking the kickstarter components for wear 9 Starter gear 1 Check the bearing for clearance (the starter gear must be in permanent mesh with the outer clutch hub). 5 7 8 Intermediate starter gear 2 Check the bearing for clearance. 6 4 3 Kick starter shaft 3 Check the toothing for signs of wear. 1 Ratchet gear 4 Check the ascending surface and the toothing for signs of wear. 2 Stop bolt 5 Check for signs of wear. Replace the seal ring 6 A A NOTE: Due to a parts change from 2000 onwards the seal ring is blue-green and is to be mounted with the seal lip to the outer side. Preassembly of kickstarter shaft B B – Clamp kickstarter shaft with toothed end in vice (use soft jawcovers). – Mount circlip 7 in lower ring groove. – Fit spring guide 8 with collar facing downwards and circlip 9 with sharp edge facing upwards. – Remove kickstarter shaft from vice and fit ratchet gear spring. – Mount the ratchet gear 4 on the kickstarter shaft in such a way that the markings A and B coincide. Clutch cover Balancer shaft bearing bk Use the bearing extractor tool with insert to remove the grooved ball bearing from the bearing seat. Insert the new bearing into the seat and ensure flush fit. Seal ring bl Use a screwdriver to lever the old shaft seal ring out of the clutch cover. Insert the new shaft seal ring and ensure flush fit. 10 11 14 13 Replacing absorbing elements of the outer clutch hub – Drill open the clutch rivets bm in area of the retaining bracket bn and take off the parts. NOTE: When performing repair work always exchange all 8 absorbing elements. ! CAUTION ! DAMPING ELEMENTS ARE WIDER THAN THE PRIMARY GEAR CROWN bo. TO ENSURE THAT THE OUTER CLUTCH HUB AND RETAINING BRACKET ARE POSITIONED DIRECTLY ON THE PRIMARY GEAR CROWN, THE PARTS MUST BE HELD IN POSITION UNDER TENSION WITH THE CLUTCH RIVETTING TOOL C BEFORE RIVETTING. THE 12 – Apply the special tool as shown, screw together and lock the rivets with a pointed mandrel and a round mandrel. C Locking pressure for the pointed mandrel: approx. 4000 kg Locking pressure for the round mandrel: approx. 5000 kg 5-17D 7 9 13 11 12 10 8 1 14 Art.-Nr. 3.206.006 -E LOCTITE 243 3 4 From model 2003 on 5 2 6 Checking the clutch components for wear Thrust bearing 1 – Check for signs of wear. Push rod 2 – Check the face side for signs of wear. Repair manual KTM LC4 Clutch release shaft 3, sealing cup 4 and needle bearing 5 – Check for damage and signs of wear. Clutch pressure springs 6 – Minimum length: 34.5 mm (1.36 in) (length/new spring: 37 mm (1.457 in)). Replace all 6 springs if necessary. Clutch discs 7 – Clutch discs must be plane. 7 steel discs ≠ 1.5 mm (0.066 in) must be free of grooves. 8 lining discs ≠ 2.7 mm (0.106 in), wear limit: 2.5 mm (0.1 in) Inner clutch hub 8 – Check both the exterior and the interior toothing for signs of wear. Needle bearing 9 – Check for signs of wear. Outer clutch hub bk – Check if all rivets bm are tight. Absorbing elements bl Power transmission from the primary drive to the clutch is cushioned by rubber elements bl. These rubber elements must be checked in the course of normal checking for signs of wear. It is recommended to check the elements while disassembling the engine. Try to turn the outer clutch hub after removing the inner clutch hub (engine will lock). Dead travel should be impossible. Check O-ring bo for brittleness and cracks. If the cross section of the O-ring is oval (deformed) replace the O-ring. 5-18D Checking the shift mechanism components for wear B Shift forks 1 Check the fork leaf for signs of wear. Check the shift roller driving pin 2 for signs of wear. 7 8 5 9 10 11 Shift rolls 3 Check the shift rolls for hairline cracks and pressure marks. Additionally, make sure that the shift rolls turn easily on the driving pins 2 of the shift forks. Shift roller 4 Check the shift grooves for signs of wear. Check the two grooved ball bearings of the shift roller for wear. Slide plate 5 Check the contact surfaces for signs of wear. Check the return surface of the slide plate for signs of wear (replace in the case of deep grooves). 1 2 4 1 3 3 1 Slide guides Check clearance (maximum clearance between guide bolt and slider 0.70 mm / 0.027 in.). Guide bolt 7 Check for tight fit and signs of wear. 3 Preassembly of shift shaft – Push steel disc 8 (14x28x2 mm) onto shift shaft. – Mount the return spring 9, positioning the offset A on the side of the shift quadrant. A – Mount spring sleeve bk with shallower collar facing shift quadrant. – Cross return spring legs and hook in shift quadrant. – Grease and mount both O-rings bl. 5-19D Shift mechanism support 2 – If the grooved ball bearing 1 of the shift roller must be exchanged, press the new grooved ball bearing all the way into the seat. 1 ! CAUTION ! TO PREVENT DAMAGING OF THE SHIFT MECHANISM SUPPORT, DO NOT APPLY EXCESSIVE FORCE WHEN INSERTING THE GROOVED BALL BEARINGS. – Apply Loctite 243 to the screw and fix the bearing. – The new needle bearing of the kickstarter shaft 2 has to be pressed in flush. Balancer shaft Check bearing seat A for wear and tear. 3 A Check three allan head bolts 3 for tight fit. Disassembling and reassembling the water pump Repair manual KTM LC4 Art.-Nr. 3.206.006 -E 5 10 9 Remove the water pump cover 4 together with the gasket. – Remove circlip 5 from the water pump shaft 6 and pull shaft and water pump wheel 7 out of the grooved ball bearings. 6 8 11 7 4 – If grooved ball bearings 8 are replaced, remove circlip 9 and shaft seal ring bk and press out bearing. – Properly lubricate new grooved ball bearings and press in to stop with the open sides facing each to them. – Mount circlip 9. – Cover new shaft seal ring with Loctite 648 and press in with the printing facing outward. – Lubricate water pump shaft and mount carefully so as to not damage sealing lips of shaft seal ring and check for smooth working. – Mount circlip 5 and water pump cover 4 with gasket. – Finally, remove silicone from the sealing flange and mount 2 new O-rings bl. 5-20D Important note regards working on transmission – Fix the main shaft or countershaft, respectively, in the vise (use special vise jaws to avoid damaging of the shafts) and remove the gear wheels. – Clean and check all parts. 11 Always use new lock washers when performing repair work on the transmission ! 10 Check the tooth profiles of transmission shafts and sliding gears for signs of wear. Slide the sliding gears onto the transmission shafts and check the toothing for easy operation. 9 Check the pivot points of the transmission shafts. Mount the idler gears with the bearings on the transmission shafts and check for clearance. Check the needle bearings of the idler gears. 8 7 Assembling the main shaft 6 5 NOTE: Check all gears for smooth operation. 4 3 2 1 – Mount the main shaft in a vise with the gearwheel facing downwards (use protective jaws). – Mount the needle cage 1 and slide the 3rd gear 2 with the shift dogs facing upwards. – Mount stop disc 3 (22.7x32x1.5 mm) and the circlip 4 with the sharp edge facing up. – Mount 4th gear 5 with the shift groove facing down. – Secure it with the circlip 6 with the sharp edge down and mount the stop disc 7 (22.7x32x1.5 mm). – Mount needle cage 8 and 5th gear 9 with the shift dogs down. – Mount 2nd gear bk and stop disc bl (20.2x35x1 mm). 5-21D Important note regards working on transmission 16 – Fix the main shaft or countershaft, respectively, in the vise (use special vise jaws to avoid damaging of the shafts) and remove the gear wheels. – Clean and check all parts. 15 Always use new lock washers when performing repair work on the transmission ! Check the tooth profiles of transmission shafts and sliding gears for signs of wear. 14 Slide the sliding gears onto the transmission shafts and check the toothing for easy operation. Check the pivot points of the transmission shafts. 13 Mount the idler gears with the bearings on the transmission shafts and check for clearance. 12 Check the needle bearings of the idler gears. 11 Assembling the counter shaft Art.-Nr. 3.206.006 -E 10 – – – – 9 – – – – 8 – Mount counter shaft in vise with collar facing downwards. Oil and mount needle cage 1. Slide 2nd gear 2 over needle cage with collar facing downwards. Mount stop disc 3 (22.7x32.0x1.50 mm) with clearance towards gear wheel and circlip 4 with sharp edge facing upwards. Mount 5th gear 5 with shift groove facing upwards. Fit circlip 6 with sharp edge down and stop disc 7 (22.7x32.0x1.50 mm). Mount needle cage 8 and fit 4th gear 9 with shift dogs facing up. Mount stop disc bk (22.7x32.0x1.50 mm) and circlip bl with sharp edge facing up. Fit 3rd gear bm with shift groove down and mount stop disc (22.2x35.0x1.50 mm) bn. Mount needle cage bo, 1st gear bp with collar facing up and fit stop disc (20.2x35.0x1.0 mm) bq. 7 – 6 NOTE: A roller bearing was installed in the 660 SMC model, thus a stop disc is unnecessary. Check all gears for smooth operation. Repair manual KTM LC4 5 4 3 2 1 5-22D Removing the intermediate gear – – – – Remove the starter cover. Pull out the bearing bolt 1. Remove the intermediate gear and the needle bearing. Check the parts for signs of wear. – Insert the intermediate gear with the collar downward into the housing for preassembly. – Oil the needle bearing and install it with the bearing bolt. – Do not yet replace the starter cover. 1 Checking the freewheel 2 3 – Insert the freewheel gear 2 into the freewheel. – The freewheel gear must turn clockwise. – The freewheel gear must lock without empty run if turned anticlockwise. – Check the reduction gear 3 and the needle bearings for signs of wear. – Check the needle bearing of the freewheel gear for signs of wear. Replacing the freewheel hub – Squeeze the spreader ring 4 with the circlip pliers and remove it together with the freewheel. – Check the freewheel segments for signs of wear. – Check the freewheel hub sections at the freewheel running surface for signs of wear. – Heat the flywheel to a temperature of approx. 80° C (176° F) and remove the 6 bolts. 4 ! ! CAUTION MAKE SURE THAT THE FLYWHEEL IS NOT HEATED BEYOND AVOID LOOSENING OF THE MAGNETS. 80° C (176° F) TO – Carefully tap the side of the freewheel hub with a plastic hammer and take off the freewheel hub. A – Apply Loctite 648 to the flange surface A of the flywheel and the freewheel hub. – Mount the freewheel hub on the flywheel. – Apply Loctite 648 to the thread of the bolts and tighten them crosswise (18 Nm). ! ALWAYS USE NEW BOLTS (12.9) CAUTION AND APPLY LOCTITE 648 ! TO THE THREADS. – Thoroughly oil the free-wheel and insert it into the freewheel hub. – Insert the spreader ring into the groove with a pair of circlip pliers and make sure that it properly rests in the groove. Electric starter motor 5 – The starter showed only slight signs of wear after 10.000 starting processes, and exchanging individual parts must be considered uneconomical. Therefore, such work is not described in the present documentation. – Exchange the O-ring 5 at the starter flange (incl. in the gasket set). 5-23D Ignition (Kokusan 4K2) General information The measurements described below will only reveal severe problems. Coil short circuits leading to weak ignition sparks or low generator output, respectively, can only be detected with the help of an ignition test bench. In the case of malfunction always check the cables and the plug and socket connections of the ignition system first. Make sure to select the correct measuring range when performing measurements. LOCTITE 648 LOCTITE 243 LOCTITE 243 LOCTITE 648 SILICON Checking the stator and the pulse generator (Kokusan 4K2) Art.-Nr. 3.206.006 -E Use an ohmmeter to perform the following measurements: NOTE: The measuring must be performed at a temperature of 20° C. Otherwise significant deviations must be expected. MEASUREMENT Stator Pulse generator CABLE COLORS red/black – black/red yellow – black/red yellow – red/black white – green RESISTANCE 0.45 – 0.56 Ω 80 – 120 Ω Replace the stator and/or the pulse generator if the measured values deviate significantly from the setpoint values or in the case of continuity between one of the cables and ground. Replacing the stator (Kokusan 4K2) Repair manual KTM LC4 – Loosen the 3 bolts and remove the stator. – Insert a new stator into the ignition cover. – Apply Loctite 243 to 3 new bolts and tighten the bolts. – Insert the cable guide in the opening provided for that purpose in the ignition cover. 5-24D Ignition (SEM) General information The measurements described below will only reveal severe problems. Coil short circuits leading to weak ignition sparks or low generator output, respectively, can only be detected with the help of an ignition test bench. In the case of malfunction always check the cables and the plug and socket connections of the ignition system first. Make sure to select the correct measuring range when performing measurements. + POLE – POLE MEASURE VALUE black red 1.7 kΩ red black 1.7 kΩ black green 165 Ω +/- 20 Ω green red 1.7 kΩ yellow yellow 1.0 Ω Checking the stator (SEM) Perform the measurements indicated to the left with an ohmmeter. NOTE: The measuring must be performed at a temperature of 20° C. Otherwise significant deviations must be expected. The stator must be exchanged if any of the measured values deviates significantly from the respective nominal value or in the case of continuity between one of the cables and ground. Replacing the stator (SEM) – Remove bolt 1 with retaining bracket. – Remove the three clamp bolts 2 and lift the stator out of the ignition cover. 2 1 – Mount the new stator in such a way that the timing mark A is visible in the checking hole on the rear side. – Apply Loctite 243 to the threads of the bolts 2 and insert the bolts without, however, tightening them yet. – Apply Loctite 243 to the thread of bolt 1, turn the stator clockwise all the way to the stop. – Fix the cable strand with retaining clips and insert the rubber cable guide into the opening provided for that purpose. – Turn the stator until the mark becomes visible in the peephole. Then tighten the bolts 2. A 5-25D Ignition (Kokusan 4K-3) General information The measurements described below will only reveal severe problems. Coil short circuits leading to weak ignition sparks or low generator output, respectively, can only be detected with the help of an ignition test bench. In the case of malfunction always check the cables and the plug and socket connections of the ignition system first. Make sure to select the correct measuring range when performing measurements. LOCTITE 243 LOCTITE 243 LOCTITE 243 Checking the stator (Kokusan 4K-3) Use an ohmmeter to perform the following measurements. Note: The measuring must be performed at a temperature of 20° C. Otherwise significant deviations must be expected. Art.-Nr. 3.206.006 -E Replace the stator if the measured values deviate significantly from the setpoint values. Ignition 4K-3 2 Measure Cable colours Resistance Pulser coil red – green 100 Ω 20% Stator black/red – red/white 12,7 Ω 20% Charging coil ground – yellow 0,65 Ω 20% white – yellow 0,16 Ω 20% Installing a new stator (Kokusan 4K-3) 1 3 1 4 Repair manual KTM LC4 3 4 – Remove the 2 bolts 1 and take the cover plate 2 out of the ignition cover. – Remove the 2 bolts 3 of the pulse generator and the 2 bolts 4 of the stator. – Undo bolt 5 and take the retaining platelet out of the ignition cover. Take the stator and the pulse generator out of the ignition cover. NOTE: When reassembling the unit, degrease and apply Loctite 243 to the threads of all bolts. – Put the new stator into the ignition cover and fix it with the two bolts 4. – Position the pulse generator in the ignition cover and fix it with the two bolts 3. – Put the cable guide into the recess provided for this purpose and fix the cover plate 2 with the two bolts 1. – Position the wiring harness, taking care to avoid tension, and use the retaining platelet and the bolt 5 to fix it in the ignition cover. 5 6-1D ASSEMBLING THE ENGINE Repair manual KTM LC4 Art.-Nr. 3.206.006 -E INDEX MOUNTING THE KICKSTARTER UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-2 MOUNTING TRANSMISSION AND SHIFT MECHANISM . . . . . . . . . . . . . .6-2 ADJUSTMENT OF RETURN SPRING . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-4 PRETENSIONING OF THE STARTER SPRING . . . . . . . . . . . . . . . . . . . . . . .6-4 MOUNTING CRANKSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-4 ASSEMBLY OF ENGINE HOUSING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-5 MOUNTING OIL FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-6 MOUNTING THE ENGINE SPROCKET . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-6 MOUNTING THE TIMING GEAR AND THE TIMING CHAIN . . . . . . . . . . . .6-7 MOUNTING THE OIL PUMPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-7 MOUNTING THE BALANCER SHAFT AND THE PRIMARY PINION . . . . . . .6-8 MOUNTING THE CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-8 MOUNTING THE CLUTCH DISCS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-9 INSTALLING THE CLUTCH RELEASE SHAFT . . . . . . . . . . . . . . . . . . . . . . . .6-9 ADJUSTING THE CLUTCH RELEASE . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-10 MEASURE DIMENSION „Y“ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-10 MOUNTING PISTON AND CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . .6-10 MOUNTING THE CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-11 MOUNTING THE CAMSHAFT, TIMING MARKS . . . . . . . . . . . . . . . . . . . .6-12 MOUNTING THE WATER PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-13 MOUNTING THE CYLINDER HEAD TOP SECTION . . . . . . . . . . . . . . . . .6-14 MOUNTING THE AUTOMATIC TENSIONER . . . . . . . . . . . . . . . . . . . . . .6-14 AUTOMATIC DECOMPRESSION TESTING . . . . . . . . . . . . . . . . . . . . . . . .6-14 ADJUSTMENT OF VALVE CLEARANCE . . . . . . . . . . . . . . . . . . . . . . . . . .6-15 MOUNTING THE CLUTCH COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-15 MOUNTING THE ELECTRIC STARTER DRIVE . . . . . . . . . . . . . . . . . . . . . .6-16 MOUNTING THE IGNITION (KOKUSAN) . . . . . . . . . . . . . . . . . . . . . . . .6-16 ADJUSTING THE PULSE GENERATOR . . . . . . . . . . . . . . . . . . . . . . . . . . .6-17 MOUNTING THE IGNITION (SEM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-17 ADJUSTMENT OF IGNITION POINT (SEM) . . . . . . . . . . . . . . . . . . . . . . .6-18 MOUNTING THE EPC WIRING HARNESS . . . . . . . . . . . . . . . . . . . . . . . .6-18 MOUNTING THE IGNITION (KOKUSAN 4K-3) . . . . . . . . . . . . . . . . . . . .6-19 ADJUSTMENT OF IGNITION POINT (KOKUSAN 4K-3) . . . . . . . . . . . . . .6-19 MOUNTING THE OIL HOSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-20 MOUNTING THE CLUTCH RELEASE LEVER . . . . . . . . . . . . . . . . . . . . . . .6-20 MOUNTING THE ELECTRIC STARTER MOTOR . . . . . . . . . . . . . . . . . . . .6-20 MOUNTING THE WATER HOSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-20 POURING IN ENGINE OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-21 MOUNTING THE KICKSTARTER AND THE SHIFT LEVER . . . . . . . . . . . . .6-21 6 6-2D – Place left-hand housing half in engine work stand. 1 Mounting the kickstarter unit – Insert stop disc (22.2x35x2 mm), starter gear 1, needle bearing and stop disc 2 (22.2x30x1.5 mm) into housing. 2 – Insert the pre-assembled kickstarter shaft into the bearing seat, putting it through the starter gear. Make sure that the starter spring slips into opening A of the housing. A Mounting transmission and shift mechanism – Insert stop disc (20.2x35x1 mm), 1st gear wheel 3 with collar facing down into the housing and the needle bearing into the idler gear. Art.-Nr. 3.206.006 -E 3 NOTE: A roller bearing was installed in the 660 SMC model, thus a stop disc is unnecessary. Repair manual KTM LC4 – Mount transmission shafts together and slightly turn them. – Grease the driving pins of the shift forks and mount the shift rollers 4. – Hook shift fork with legs of same length in the sliding gear of the main shaft. – Fit the other two shift forks into the gears of the counter shaft, paying attention to the marks applied during disassembly. ! USED 4 CAUTION ! SHIFT FORKS SHOULD BE MOUNTED IN THE SAME SLIDING GEAR AS BEFORE. 6-3D 2 1 3 – Insert shift roller 1 into the housing with the holder for the locking piece facing up. – Hook the shift forks into the shift roller and mount shift rails 2 + 3. The shorter shift rail 3 must be fitted to the main shaft. – Before mounting the shift mechanism support, check whether the two dowels have been fitted. – Mount shift mechanism support, secure the two bolts 4 with Loctite 243 and tighten. 4 4 – Put the washer (6.2x18x2 mm), the locking lever, the locking spring bushing and the locking lever spring onto the third bolt. – Apply Loctite 243 to the thread of the bolt and mount it. 6 – Pull locking lever 5 away from the shift roller. – Put the shift drum locating device 6 onto the shift roller, apply Loctite 243 to the thread of the bolt and fix the shift drum locating device. 5 – Oil the O-rings and grease the shank of the shift shaft. – Slide preassembled shift shaft into kickstarter shaft. – At the same time, push back the slide plate 7 and make sure that the ends of the return spring 9 are resting against the centering cup of the shift mechanism support 8. 9 8 7 6-4D Adjustment of return spring – Engage second or third gear. – Check free travel of slide plate and check shift pin play. – The free travel of the slide plate is the path this component travels until the shift roller is moved. The return spring pressure will be felt. Proceeding from the basic position, this free travel A should be identical for upward and downward movement. – If necessary, the free travel must be readjusted by adjusting the return spring. – For this purpose, remove the shift shaft and bend the return spring by an appropriate amount at points B using a pair of pliers. Refit shift shaft. After the shifting shaft has been fitted, the return spring must rest against shift pin 1 and against the centering cup on the shift mechanism support. – If necessary, bend the return spring accordingly. 1 B Pretensioning of the starter spring Art.-Nr. 3.206.006 -E – Fit kickstarter onto kickstarter shaft, turn one revolution in starting direction and hold in this position. – Mount the stop bolt 2 together with a new seal ring and tighten it manually. ! CAUTION ! IT MUST BE POSSIBLE TO MOUNT THE STOP BOLT WITHOUT APPLYING EXCESSIVE FORCE. IF IT IS NOT POSSIBLE TO MOUNT THE STOP BOLT MANUALLY, TURN THE KICKSTARTER SHAFT FURTHER AGAINST THE FORCE OF THE SPRING UNTIL THE STOP BOLT CAN BE MOUNTED. – Move kickstarter to stop and remove. – Tighten stop bolt 2 with 50 Nm. 2 – Place O-ring 3 (22x1 mm) and inner ring 4 of roller bearing on the counter shaft with the collar facing the gear. – Mount stop disc 5 (20.2x35x1 mm) onto the main shaft. Repair manual KTM LC4 4 3 5 Mounting crankshaft – Grease the shaft seal ring of the crankshaft and thoroughly oil the roller bearing of the crankshaft. – Fit mounting sleeve onto crankshaft and place crankshaft into bearing. 6-5D Assembly of engine housing – Make sure both dowels are in place in the left housing half, and put gasket on the sealing surface. Use a little bit of grease to hold the gasket in place. – Grease all shaft seal rings in the left side of the housing. – Oil all bearings in the right side of the housing and put on the housing half. If necessary, tap lightly with a plastic mallet and turn transmission shafts. – Check to make sure that the gasket is in the proper position before final assembly. – Grease housing bolts (threads and contact surfaces of bolts heads). Insert bolts and assemble the housing (see sketch for bolt lengths). – Check all the shafts for smooth operation before and after tightening with 7-8 Nm. – Mount case in mounting rack and check function of gear-change by engaging all gears. – Check crankshaft axial clearance (0.03 - 0.12 mm) (0.0012 - 0.0047 in) and fit crankshaft locking bolt. SX, SXC M6x30 M6x55 SC M6x65 M6x30 M6X55 NOTE: On Adventure-models bolts M6x35 are used instead of the two upper bolts M6x30. LC4-E M6x65 M6x30/35 M6x30 M6x55 M6x95 640 LC4 2003 on M6x65 M6x30/35 M6x55 M6x55 M6x30 NOTE: On Adventure-models bolts M6x35 are used instead of the two upper bolts M6x30. 6-6D SXC/SMC 2003 on M6x65 M6x55 M6x30 Mounting oil filter – Fit oil filter with rubber gasket onto the connection in the oil filter cover. – Fit a new O-ring into the oil filter cover groove or use new gasket and fix the oil filter cover with the 3 bolts, tighten bolts with 5 Nm. Mounting the engine sprocket Art.-Nr. 3.206.006 -E 3 – Lubricate O-ring (25x2 mm) with oil and slide over countershaft. – Slide distance bushing 1 in position so that O-ring is in correct position. NOTE: The distance bushing for Duke and Supermoto-models is 2mm thicker. 2 ! DO CAUTION ! NOT REVERSE DUST LIP OF THE SHAFT SEAL. – Fit the engine sprocket with the collar facing the housing. 1 NOTE: For Duke and Supermoto-models an additional 2 mm washer is used. 4 – Apply Loctite 243 to thread of sprocket bolt. – Mount spring retainer 2 and sprocket bolt 3. – Apply counterpressure with the sprocket holding spanner and tighten sprocket bolt. Repair manual KTM LC4 NOTE: Tighten bolts with quality 8.8 to 40 Nm, bolts with quality 10.9 to 60 Nm. 5 NOTE (from model 2003 on): A collar nut 4 and a lock washer 5 are installed in some of the models instead of a collar screw. Tightening torque off the collar nut: 60 Nm 6-7D Mount the timing gear and the timing chain – Insert woodruff key for timing gear into crankshaft and fit timing gear onto crankshaft with high collar towards housing. – Fit timing chain onto timing gear and draw up through chain tunnel. 3 1 4 – Insert the timing chain guide 1, apply Loctite 243 to the Allen head bolt 2 and mount. – Apply Loctite 243 to the thread of the flat-head screw 4. – Fasten timing chain tensioner 3 with flat head screw. – Check timing chain tensioner for smooth operation. 2 – Insert the safety device 5, apply Loctite 243 to the Allen head bolt 6 and mount. 6 5 Mounting the oil pumps 7 8 – Clean the sealing surfaces and install the oil pumps in the engine housing (A M6x25!) – Degrease the threads and use Loctite 243 to secure the bolts in their position. – Degrease the threads of both bolts 7, apply Loctite 243 and mount the retaining bracket 8. A – Put the stop discs (8.1x15x0.5 mm) onto the oil pump shafts. – Insert the bearing needles into the oil pump shafts and slide on the oil pump gears (high collars must face the casing; the small oil pump gear must face the upper oil pump). NOTE: From model 2002 onwards both oil pumps are fitted with the same size of oil pump gear. – Put on the upper stop discs 9 (8.1x15x0.5 mm) and mount the locking discs bk. 10 9 6-8D Mounting the balancer shaft and the primary pinion – Fit balancer shaft in the bearing. – Mount woodruff key in crankshaft and place primary pinion on the crankshaft. When doing so, adjust the teeth of the primary pinion and the balancer shaft in such a way that the markings A and B coincide. – Apply Loctite 243 to the crankshaft thread. – Mount spring ring and hexagon nut and tighten hexagon nut to 170 Nm. B A ! CAUTION ! IF THE BALANCER SHAFT IS NOT INSTALLED ALSO REMOVE BOTH GROOVED BALL BEARINGS (IN THE CLUTCH COVER AND IN THE ENGINE HOUSING). OTHERWISE THE GROOVED BALL BEARINGS WOULD DROP OUT OF THE BEARING SEATS AND CAUSE ENGINE DAMAGE AS SOON AS THE ENGINE HEATS UP. Mounting the clutch 1 – Fit kickstarter intermediate gear 1 onto counter shaft with clearance space towards housing. – Slide the inner ring and the needle bearing 2 onto the main shaft. 2 Art.-Nr. 3.206.006 -E – Fit outer clutch hub and outer stop disc 3 (22.2x35x3 mm). 3 Repair manual KTM LC4 – Degrease the thread of the main shaft. – Place inner clutch hub and a new safety plate on the main shaft. – Coat the thread of the main shaft with Loctite 243 and mount hexagon nut. – Fit clutch holder and tighten hexagon nut to 100 Nm (60 ft.lb.). – Remove clutch holder. – Check clutch hub and main shaft for smooth operation and axial clearance. – Secure outer clutch hub hexagon nut by bending the safety plate up into place. 6-9D Mounting the clutch discs – Thoroughly oil the O-ring 1 and put it onto the inner clutch hub. – Oil the lining disc 2 (internal diameter: 127 mm) and mount it, making sure that the disc encircles the O-ring (see illustration). 1 2 – Thoroughly oil all clutch discs before mounting. – Alternately mount 1 steel disc and one lining disc. NOTE: The last disc must be a lining disc. ! MOUNT CAUTION ! ALL STEEL DISKS WITH THE SHARP EDGE FACING DOWNWARD. B – Grease the end of the push rod with Molykote grease and fit the pressure cap together with the push rod. – When mounting the pressure cap make sure that bore A in the pressure cap and the pin B of the inner clutch hub coincide. A – Place the springs in the pressure cap and fit the HH srews with spring retainers. – Secure carefully to 6 Nm in a diagonal pattern, to avoid any damage to the inner clutch hub thread. NOTE: – Use offset instead of flat spring retainers for 640 ccm engines. – From model 2000 onwards spring retainers 6,5x20x2 replaced spring retainers 6,2x20x3,2, these can be used for all models with 540, 620 and 640 engines. Installing the clutch release shaft – Oil needle bushings in engine housing. – Insert the grooved ring 3 into the housing with the open side up. – Check for the right position of the circlip 4 on the clutch release shaft. – Slide the release shaft into the housing until it lies on the clutch push rod. 4 3 6-10D – Turn the release shaft clockwise until it glides a bit further into the housing. The push rod now sits on the release shaft. – Apply Loctite 243 to the bolt (s). – Fasten the retaining bracket for the clutch release 1 with bolt(s). 1 Adjusting the clutch release – Turn the clutch release shaft clockwise to stop. – The slot on the front side of the release shaft should now be parallel to the sealing surface of the housing (see ill.). PA R A L L E L – To adjust the clutch release remove pin 2 and turn the push rod 3 with a screwdriver until the desired setting is achieved. – Once you have completed the adjustment, the push rod is to be secured with a pin. Art.-Nr. 3.206.006 -E 3 ! CAUTION ! TO MAKE SURE THAT THE CLUTCH DISENGAGES PERFECTLY, THE CLUTCH RELEASE MUST BE PROPERLY ADJUSTED. 2 Repair manual KTM LC4 Sealing surface of the clutch slave cylinder push rod DIMENSION „Y“ Measure the dimension „Y" (from model 2003 on) NOTE: The dimension „Y" must be adjusted to make sure the clutch release operates correctly. The dimension „Y" is the distance between the sealing area of the clutch slave cylinder and the pushrod. – Oil the pushrod and insert in the main shaft all the way in to the stop. – Measure the distance between the mounting face (without the gasket) of the clutch slave cylinder to the pushrod using a depth gauge. – To adjust, remove the splint 2 and turn the pushrod 3 with a screwdriver. – After making the adjustment, lock the pushrod with the splint again. Dimension „Y" = 2.75 mm Mounting piston and cylinder – Lubricate the piston pin eye in the connecting rod and the piston pin with oil. – Mount piston and secure piston pin with 2 new wire circlips. ! CAUTION ! THE ARROW ON THE PISTON HEAD MUST POINT IN THE DIRECTION OF TRAVEL. MOUNT WIRE CIRCLIPS IN „6 O’CLOCK” OR „12 O’CLOCK” POSITION (SEE ILL.). 12 o’clock-pos. 6 o’clock-pos. 6-11D – Cut off the section of the housing gasket protruding around the cylinder flange and mount 2 dowels. – Apply sealing compound to the sections near the chain tunnel and mount the cylinder base gasket. NOTE: – To facilitate the installation of the cylinder it is recommended to place a rubber band (see illustration) around the timing chain guide and the timing chain tensioner. – Oil the piston, adjust the piston rings (piston rings must be turned 120 ° against each other) and mount the piston mounting ring. – Only for 640 LC4 engines a black cylinder base gasket (0,7 mm thickness) is used, the other LC4 engines need the green gasket (0,5mm thickness). – Slide the cylinder over the piston and remove the mounting ring. ! ! CAUTION APPLY PARTICULAR CARE WHEN MOUNTING THE CYLINDER! IS EXTREMELY FRAGILE. THE OIL SCRAPER RING – Hook in the preassembled microfilter with the holding device onto the rear studs and mount the collar nuts 1 at the cylinder base. – Tighten collar nuts with 40 Nm (30 ft.lb.) crosswise. – Then mount the bracket 2 and attach the microfilter. NOTE: The upper edge of the piston is higher than the upper edge of the cylinder when the cylinder is screwed down. 1 2 Mounting the cylinder head – Check both dowels within the cylinder for proper fit. – Mount cylinder head gasket and fit cylinder head. – Oil the 4 bolt (threads and contact surfaces of bolt head) and then mount with new copper seal rings. – Tighten collar bolts crosswise in three rounds up to the prescribed torque of 50 Nm. During the first round only tighten until a slight resistance is felt. 5 – Mount M8 collar nuts 3 on the front and rear side of cylinder and tighten. – Mount and tighten bolts 4. – Put a new seal ring on the chain guide bolt 5 and degrease the thread. – Apply Loctite 243 to the thread of the chain guide bolt, mount and tighten it (30 Nm). ! BEFORE 4 3 CAUTION ! MOUNTING THE CHAIN GUIDE BOLT MAKE SURE THAT THE OPENING OF THE TIMING CHAIN GUIDE IS VISIBLE THROUGH THE THREADED HOLE. IF THIS IS THE CASE THE CHAIN GUIDE BOLT CAN EASILY BE MOUNTED WITHOUT EXERTING EXCESSIVE FORCE. 6-12D Mounting the camshaft, timing marks 1 B A Repair manual KTM LC4 Art.-Nr. 3.206.006 -E C A B C tensioned – Fit the camshaft gear into the timing chain so that mark A (a point) is aligned with the top surface of the cylinder head when the timing chain strand tensioned. – Tilt engine to one side and place circlip 1 on camshaft gear. – Slide grooved ball bearing flush onto the preassembled camshaft and fit the camshaft into the camshaft gear so that the mark B and mark C are aligned. 6-13D – Lubricate the needle bushing 1 with oil and slide it onto the camshaft. – Mount camshaft together with bearing and circlip 2 into cylinder head. 1 2 – Degrease the threads in the camshaft and the driving bolt and apply Loctite 243. – Mount the driving bolt together with the lock washer and the washer (10x28x3 mm) and tighten (35 Nm/25 ft.lb). Mounting the water pump 3 – Loosen crankshaft locking bolt and turn crankshaft until groove 3 is at a position vertical to the sealing surface for the cylinder head top section. – Coat O-ring of water pump with sealing compound (Three-Bond) and carefully mount the water pump. The flat part of the water pump shaft must be introduced into the groove of the HH bolt. THE ! MARKING 4 CAUTION ! LOCATED ON THE HOUSING OF THE WATER PUMP MUST BE FLUSH TO THE SEAL SURFACE. 4 6-14D 2 2 Mounting the cylinder head top section – Clean the sealing area of the cylinder head top section and apply a thin layer of sealing compound. – Fit dowel in the area of the spark plug. – Carefully position cylinder head top section (do not jam with water pump) and mount bolts. ! COPPER 3 1 1 CAUTION 5 ALLEN SEAL RINGS MUST BE FITTED TO THE HEAD BOLTS ! 1, 2 AND 3. – Tighten bolts 1 and 2 to 8 Nm diagonally. – Tighten bolts 2 to 15 Nm. – Tighten all other bolts of the cylinder head top section with 8 Nm. Mounting the automatic tensioner – Fit preassembled automatic tensioner with gasket into the cylinder. – Mount the clamp 4 and two bolts with copper seal rings. ! CAUTION ! IF THE RATCHETING PAWL IS NOT ENGAGED INTO THE FIRST NOTCH THIS WILL CAUSE EXCESSIVE TENSION OF THE CHAIN. – Fit pressure spring and plug 5 with gasket and tighten with 20 Nm. Art.-Nr. 3.206.006 -E 4 5 Automatic decompression testing – Rotate the crankshaft in the usual direction of rotation (i.e. forward). After every other rotation, the decompression cam must be clearly heard to click as it disengages. Repair manual KTM LC4 NOTE: If turning of the engine does not produce a click of the decompression cam, first of all check the tightening torque of the driving bolt (camshaft gear). 6-15D Adjustment of valve clearance – Adjust piston to ignition top dead center (check marks of flywheel) and screw crankshaft locking bolt back in. ! ! CAUTION IF THE PISTON IS NOT IN IGNITION TDC, VALVES ARE OPENED AND A CORRECT ADJUSTMENT IS NOT POSSIBLE - IN THAT CASE CRANKSHAFT MUST BE MOVED A FULL TURN. – Valve clearance A is measured at cold engine between valve stem and adjusting screw. VALVE VALVE VALVE VALVE VALVE VALVE CLEARANCE CLEARANCE CLEARANCE CLEARANCE CLEARANCE CLEARANCE 400 540 620 625 640 660 : : : : : : INTAKE INTAKE INTAKE INTAKE INTAKE INTAKE 0.20 0.15 0.15 0.15 0.15 0.15 mm mm mm mm mm mm / / / / / / EXHAUST EXHAUST EXHAUST EXHAUST EXHAUST EXHAUST 0.20 0.15 0.15 0.15 0.15 0.15 mm mm mm mm mm mm – Tighten counternuts with 20 Nm. – Remove the crankshaft locking bolt. A – Mount both valve covers with new gaskets and bolts with copper seal rings. – Tighten bolts with 8 Nm. – Insert and tighten spark plug with 20 Nm. Mounting the clutch cover – Pour approx. 30 ml of oil into the crankshaft journal hole. 1 2 2 – Make sure that the two dowels are mounted. – Fit new gasket and fix with dabs of grease. – Apply grease to the shaft seal ring in the clutch cover and mount clutch cover. – Fit bolts and bump rubber 1 for kickstarter. NOTE: Bolts 2 must each be provided with a copper seal ring. – Tighten bolts with 8 Nm. 6-16D Mounting the electric starter drive – – – – 1 Insert the woodruff key into the crankshaft. Slide 2 needle bearings 1 onto the bearing pin of the reduction gear. Slide the needle bearing 2 onto the crankshaft. Oil the needle bearings. 2 – Mount the freewheel gear 3 and the reduction gear 4. 4 3 Mounting the ignition (Kokusan 4K-2) Art.-Nr. 3.206.006 -E – Degrease the cones of flywheel and crankshaft. – Thoroughly oil the freewheel and mount the flywheel. NOTE: Turn the reduction gear for easier mounting of the flywheel. 4 – Mount disk with the nut. – Use the holding tool 5 to hold the flywheel and tighten the hexagon nut with 150 Nm. Repair manual KTM LC4 5 ! CAUTION ! TO AVOID DISTORTION OF THE CRANK WEB, NEVER MOUNT THE CRANKSHAFT LOCKING BOLT TO TIGHTEN THE HEXAGON NUT OF THE FLYWHEEL. – Insert 2 dowels into the housing. – Apply silicone to both sealing surfaces and mount a new gasket. – Mount the preassembled starter flange and use 4 bolts to fasten the starter flange. 6-17D Adjusting the pulse generator 3 2 1 – Turn the flywheel until the elevated section of the flywheel 1 coincides with the pulse generator 2. – Use a feeler gauge to measure the distance between the pulse generator and the flywheel. Setpoint value: 0.75 mm (0.03 in) +/- 0.2 mm (0.008 in) – If necessary undo the two bolts 3 and adjust the distance by moving the pulse generator. When mounting the two bolts secure them with Loctite 243. – Insert 2 dowels. – Apply silicone to both sealing surfaces and mount a new gasket. – Mount ignition cover and tighten all bolts. 4 – Insert a new O-ring 4 into the groove of the starter cover and fasten the starter cover with 3 bolts. Mounting the ignition (SEM) – – – – – – Block crankshaft with crankshaft locking bolt. Place woodruff key in crankshaft. Clean cones of crankshaft and flywheel and mount flywheel. Fit spring washer and collar nut. Tighten collar nut to 60 Nm. Place the O-ring into the groove of the engine housing. – Fit preassembled ignition cover and mount the 4 bolts but do not tighten. 6-18D Adjustment of ignition point (SEM) NOTE: The ignition point is adjusted after the crankshaft locking bolt has been mounted. C – Remove the plug at the ignition cover. – Turn ignition cover so that the mark C on the stator and the mark A on the flywheel are aligned. – Tighten the 4 bolts of the ignition cover. – Finally, mount the ignition cover plug. A NOTE: The 400 LC4 engine needs more preignition than the other LC4 engines. As all LC4 engines are equipped with the same ignition system, the flywheel is provided with an additional mark (groove) for the 400 LC4 engine. The ignition adjustment procedure is exactly the same. – In the 400 LC4 model the marking B (notch) must coincide with the marking on the stator. – In the 540 LC4, 620 LC4 and 640 LC4 model the marking A (2 mm bore) must coincide with the marking on the stator. A B Art.-Nr. 3.206.006 -E 2 Mounting the EPC wiring harness – Put the wiring harness through the clip at the automatic tensioner and connect all 3 cable lugs to the contact screws, making sure to connect each cable to the corresponding screw: – Connect the black/orange cable to contact screw 1. – Connect the black/green cable to contact screw 2. – Connect the black/blue cable to contact screw 3. 3 Repair manual KTM LC4 1 6-19D Installing the ignition (Kokusan 4K-3) – Block the crankshaft with the crankshaft locking bolt. – Insert the woodruff key into the crankshaft. – Clean the cone of the flywheel and the crankshaft and mount the flywheel. – Mount the spring washer and the collar nut (LH thread). – Tighten the collar nut with 60 Nm. – Insert the O-ring 1 into the groove in the engine housing. 1 – Mount the pre-assembled ignition cover. Insert the 4 bolts without tightening them yet. Adjusting the ignition point (Kokusan 4K-3) NOTE: The ignition point is adjusted while the crankshaft locking bolt is still twisted in. A C B – Remove the plug at the clutch cover. – Turn the clutch cover until mark C on the pulse generator and mark A or B, respectively, on the flywheel coincide. NOTE: In 400 LC4 engines mark B must coincide with the mark on the pulse generator. In 620/660 LC4 engines mark A must coincide with the mark on the pulse generator. – Tighten the 4 bolts of the ignition cover. – Finally, mount the plug. A B 6-20D 1 Mounting the oil hoses – Mount the two oil hoses. – Tighten banjo bolt 1 with 10 Nm and banjo bolt 2 with 15 Nm. 2 Mounting the clutch release lever – To mount the clutch release lever 3, turn the clutch release shaft clockwise as far as stop and fit the release lever as illustrated. – Tighten clamp bolt 4. 3 4 Mounting the electric starter motor – Slightly oil the O-ring on the flange of the electric starter motor. – Mount the electric starter motor and fix it with 2 bolts 5. Art.-Nr. 3.206.006 -E 5 Mounting the water hoses Repair manual KTM LC4 – Mount the two water hoses and use the four hose clamps to fasten. 6-21D up to model 2001 Pouring in engine oil from model 2002 on – Mount oil drain plug 1 with seal ring and tighten with 30 Nm. – Mount the magnetic plug 2 and tighten with 20 Nm. 1 NOTE: A third plug was installed in the 660 SMC model. Tightening torque: 20 Nm 1 2 2 – Remove the oil dipstick or the oil filler screw on the clutch cover and add engine oil (see below for quality and viscosity). Remount the oil dipstick or the oil filler screw. ! CAUTION ! – ONLY – – USE HIGH-QUALITY OILS MEETING OR SURPASSING THE QUALITY REQUIREMENTS OF JASO T903 MA (FOR SPECIFICATIONS SEE CONTAINERS). INSUFFICIENT OIL OR POOR QUALITY OIL RESULTS IN PREMATURE WEAR OF THE ENGINE. YOU MAY USE EITHER MINERAL OILS OR SYNTHETIC OILS FULFILLING THE ABOVE CRITERIA. Oil capacity (up to model 2002) : 1.40 l Oil capacity (from model 2003 on) : 1.50 l JASO T903 MA TEMPERATURE 0°C 32°F 5W/40 10W/50 Mounting the kickstarter and the shift lever – Put the kickstarter onto the kickstarter shaft, then mount bolt 3 together with a new Schnorr lock washer 4 and tighten it. – Put the V- seal ring 5 and the shift lever onto the shifting shaft. – Mount bolt 6 together with 2 Nordlock discs 7 and washer 8. – Adjust the stop rubber for the kickstarter so that it rests against the kickstarter. NOTE: As soon as the engine is assembled close all openings providing access to the engine (intake port, exhaust port, water connections, bleeding openings ...) with appropriate plugs to prevent small parts from slipping into the interior of the engine during the further installation process. 3 4 5 8 6 7 7-1D 7 ELECTRICAL INDEX Repair manual KTM LC4 Art.-Nr. 3.206.006 -E ELECTRICAL – SUPER COMPETITION . . . . . . . CHECKING THE VOLTAGE REGULATOR-RECTIFIER CHECKING THE VOLTAGE REGULATOR . . . . . . . . CHECKING THE CAPACITOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-4 . . . . .7-4 . . . . .7-4 . . . . .7-4 ELECTRICAL – LC4 COMPETITION . . . . . . . . . . . . . . . . . . . CHARGING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LEAKAGE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REMOVING THE BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHARGING THE BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHARGING VOLTAGE / CHECKING THE VOLTAGE REGULATOR CHECKING THE CAPACITOR . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE NEUTRAL SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-5 .7-5 .7-5 .7-6 .7-6 .7-6 .7-7 .7-7 ELECTRICAL – LC4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-8 CHARGING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-8 LEAKAGE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-8 REMOVING THE BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-9 CHARGING THE BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-9 CHARGING VOLTAGE / CHECKING THE VOLTAGE REGULATOR . . . . . . . .7-9 CHECKING THE CAPACITOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-10 ELECTRIC STARTER SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-11 CHECKING THE START AUXILIARY RELAY . . . . . . . . . . . . . . . . . . . . . . . .7-12 CHECKING THE AUXILIARY STARTING RELAY FOR FAULTLESS OPERATION . .7-12 CHECKING THE DIODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-12 CHECKING THE STARTER RELAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-13 CHECKING THE ELECTRIC STARTER MOTOR . . . . . . . . . . . . . . . . . . . . .7-13 CHECKING THE CLUTCH SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-14 CHECKING THE EMERGENCY OFF SWITCH . . . . . . . . . . . . . . . . . . . . . .7-14 TROUBLE SHOOTING IN THE ELECTRIC STARTER SYTEM . . . . . . . . . . . .7-14 IGNITION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-15 CDI UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-16 CHECKING THE IGNITION COIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-16 TROUBLE SHOOTING IN THE IGNITION SYSTEM . . . . . . . . . . . . . . . . . .7-16 EPC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-17 7-2D INDEX DISMOUNT / RENEW SOLENOID VALVE FOR EPC CHECK OF SOLENOID VALVE FOR EPC . . . . . . . . CONTROLLER OF THE EPC SYSTEM . . . . . . . . . . . CHECK OF EPC SYSTEM MICROSWITCH . . . . . . . REPLACING THE EPC SYSTEM MICROSWITCH . . . CHECK OF IDLE SWITCH / CONTACT SCREWS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-18 . . . . . . . . . . . . .7-18 . . . . . . . . . . . . .7-18 . . . . . . . . . . . . .7-19 . . . . . . . . . . . . .7-19 . . . . . . . . . . . . .7-19 Repair manual KTM LC4 Art.-Nr. 3.206.006 -E ELECTRICAL – DUKE-E . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHARGING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LEAKAGE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHARGING VOLTAGE / CHECKING THE VOLTAGE REGULATOR REMOVING THE BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHARGING THE BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE CAPACITOR . . . . . . . . . . . . . . . . . . . . . . . . . . ELECTRIC STARTER SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE START AUXILIARY RELAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-20 .7-20 .7-20 .7-21 .7-21 .7-21 .7-22 .7-23 .7-24 CHECKING THE AUXILIARY STARTING RELAY FOR FAULTLESS OPERATION . . .7-24 CHECKING THE DIODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-25 CHECKING THE CLUTCH SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-25 CHECKING THE EMERGENCY OFF SWITCH . . . . . . . . . . . . . . . . . . . . . .7-25 CHECKING THE STARTER RELAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-26 CHECKING THE ELECTRIC STARTER MOTOR . . . . . . . . . . . . . . . . . . . . .7-26 TROUBLE SHOOTING IN THE ELECTRIC STARTER SYTEM . . . . . . . . . . . .7-26 IDLE SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-26 IGNITION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-27 CDI UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-28 CHECKING THE IGNITION COIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-28 SPARK PLUG CONNECTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-28 CHECKING THE SIDE STAND RELAY . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-28 CHECKING THE SIDE STAND SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . .7-29 TROUBLE SHOOTING IN THE IGNITION SYSTEM . . . . . . . . . . . . . . . . . .7-29 ELECTRICAL – SXC ‘99 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-30 CHECKING THE VOLTAGE REGULATOR . . . . . . . . . . . . . . . . . . . . . . . . .7-30 CHECKING THE CAPACITOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-30 7-3D INDEX Repair manual KTM LC4 Art.-Nr. 3.206.006 -E ELECTRICAL – SC ‘99 . . . . . . . . . . . . CHECKING THE VOLTAGE REGULATOR CHECKING THE CAPACITOR . . . . . . . . CHECKING THE IGNITION COIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-31 .7-31 .7-31 .7-31 ELECTRICAL – DUKE ‘99 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-32 CHARGING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-32 LEAKAGE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-32 CHARGING VOLTAGE / CHECKING THE VOLTAGE REGULATOR . . . . . . .7-33 REMOVING THE BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-33 CHARGING THE BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-33 CHECKING THE CAPACITOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-34 ELECTRIC STARTER SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-35 CHECKING THE START AUXILIARY RELAY . . . . . . . . . . . . . . . . . . . . . . . .7-36 CHECKING THE AUXILIARY STARTING RELAY FOR FAULTLESS OPERATION . . .7-36 CHECKING THE DIODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-37 CHECKING THE CLUTCH SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-37 CHECKING THE EMERGENCY OFF SWITCH . . . . . . . . . . . . . . . . . . . . . .7-37 CHECKING THE STARTER RELAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-38 CHECKING THE ELECTRIC STARTER MOTOR . . . . . . . . . . . . . . . . . . . . .7-38 TROUBLE SHOOTING IN THE ELECTRIC STARTER SYTEM . . . . . . . . . . . .7-38 CHECKING THE IDLE SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-38 IGNITION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-39 CDI UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-40 CHECKING THE IGNITION COIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-40 SPARK PLUG CONNECTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-40 CHECKING THE SIDE STAND RELAY . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-40 CHECKING THE SIDE STAND SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . .7-41 TROUBLE SHOOTING IN THE IGNITION SYSTEM . . . . . . . . . . . . . . . . . .7-41 MEASUREMENTS WITH PEAK VOLTAGE ADAPTER (FROM MODEL 2000 ON) DYNAMIC GENERATOR VALUES 400/640 LC4-E, 625 SXC, DUKE, ADVENTURE STATIC IGNITION VALUES 400/640 LC4-E, 625 SXC, DUKE, ADVENTURE STATIC GENERATOR VALUES 400/640 LC4-E, 625 SXC, DUKE, ADVENTURE STATIC IGNITION VALUES 400/620/625 SC, 660 SMC . . . . . . . . . . . . . STATIC GENERATOR VALUES 400/620/625 SC, 660 SMC . . . . . . . . . . . . . . . . . . . . . .7-42 .7-43 .7-45 .7-47 .7-49 CHECKING SPEEDOMETER AND SPEEDOMETER SENSOR . . . . . . . . . . . .7-51 7-4D ELECTRICAL – SUPER COMPETITION Checking the voltage regulator-rectifier – Start the engine and switch on the low beam. – Connect a voltmeter to the two terminals of the capacitor (red/white cable = positive, brown cable = negative). – Accelerate the engine to a speed of 5000 r.p.m. and read off the voltage. Nominal value: 14.0 - 15.0 V If the reading significantly deviates from the nominal value above, check the capacitor. If the capacitor is intact, replace the voltage regulator-rectifier. Checking the voltage regulator The two voltage regulators are located under the right side cover at the air filter box. The voltage regulators are connected downstream of the switches. One of the voltage regulators regulates only the brake light circuit, the other regulates the circuit for the head light, the tail light, the speedometer illumination and the horn. Art Nr 320549-D A defect voltage regulator can cause different kinds of trouble: ● No voltage in the circuit In this case, the voltage regulator must be disconnected at idle speed. The voltage regulator is defect if the power consumers now work properly. If the power consumers are still not supplied with power, the switch, the wiring harness or the ignition system must be checked for defects. 1 ● Excessive voltage in the circuit The bulbs burn out. Connect a voltmeter (yellow cable = positive, brown cable = negative) to check the voltage. Start the engine and switch on the power consumers. At an engine speed of 3000 r.p.m, the voltage regulator must supply a voltage of 12.0 - 14.0 V A.C. At higher engine speeds, the limit of 14 V should not be exceeded either. If the reading significantly deviates from the nominal value, replace the voltage regulator. Repair manual KTM LC4 Checking the capacitor – Discharge the capacitor 1 by bridging the two terminals with a screwdriver and remove. – Connect the negative pole of a 12V battery with the negative terminal of the capacitor. The connection between the positive pole of the battery and the positive terminal of the capacitor (marked +) is made with a test lamp 1. – When the power circuit is closed, the test lamp must begin to light up. As capacitor charging increases, the brightness of the test lamp must decrease. – The test lamp must go out after 0,5-2 seconds (depending on the lamp capacity). – If the test lamp does not go out or does not light up at all, the capacitor is faulty. ! ! CAUTION DISCHARGE THE CAPACITOR BEFORE AND AFTER EACH TEST. WHEN INSTALLING THE CAPACITOR, MAKE SURE THAT THE TERMINALS ARE CONNECTED IN ACCORDANCE WITH THEIR MARKINGS. CONNECT RED/WHITE CABLE TO + TERMINAL. 7-5D ELECTRICAL – LC4 COMPETITION 2 ignition lock ge-r 1 3 bl ge 5 4 br bl . br . ge gr . g . o . r .. ra . s.. v . w . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .blue .brown .yellow .grey .green .orange .red .pink .black .violet .white Charging system 1 2 3 4 5 Generator Regulator-rectifier Main fuse (20 A) Battery (12V / 8 Ah) Capacitor Leakage inspection The drop test must be performed before checking the voltage regulator/rectifier – Turn off the ignition and disconnect the ground wire from the battery. – Insert an amperemeter between the ground wire and the negative pole of the battery. Setpoint value: max. 1 mA – Check for power consumers, should the measured value exceed the indicated maximum value. Example: ● defective voltage regulator-rectifier ● leak currents in the socket connectors, in the ignition lock or in the starter relay. 0,00 7-6D Removing the battery 1 – Remove the seat. – Disconnect first the negative and then the positive pole of the battery. – Remove the bolts 1 and swing the battery support with the voltage regulator-rectifier sideways. – Remove the battery. – When reinstalling the battery, connect the negative pole last. ! ! CAUTION FOLLOW THE INSTRUCTIONS OF THE MANUFACTURER WHEN FILLING A NEW THE RELEVANT SAFETY INSTRUCTIONS ARE ALSO CONTAINED IN THE USER SUPPLIED WITH THE BATTERY. BATTERY. MANUAL Charging the battery Art.-Nr. 3.206.006 -E – Remove the battery and check the charging level. Use a voltmeter to measure the voltage between the battery poles (off-load voltage). – Accurate results can only be obtained if the battery has neither been charged nor discharged during a period of 30 minutes preceding the measuring. – If the battery is empty, it can be recharged for a maximum period of 10 hours at 0.8 A and a maximum of 14.4 V. ! CAUTION ! – TO AVOID DAMAGE, DO NOT REMOVE THE LOCKING BAR – ALWAYS CONNECT THE BATTERY TO THE CHARGING UNIT BEFORE TURNING THE CHARGING UNIT ON. – WHEN RECHARGING THE BATTERY IN CLOSED ROOMS ENSURE SUFFICIENT VENTILATION. EXPLOSIVE GASES ARE RELEASED DURING THE BATTERY CHARGING PROCESS. – CHARGING TIME AND CHARGING VOLTAGE SHOULD NOT EXCEED THE STATED VALUES. OTHERWISE ELECTROLYTE WILL BE RELEASED THROUGH THE SAFETY VALVES. – AVOID QUICK CHARGING IF POSSIBLE. off load voltage Volt charging level % charging time 0.8 A >12.7 ~12.5 ~12.2 ~12.0 ~11.8 100 75 50 25 0 –– 4h 7h 11 h 14 h charging voltage max. 14.4 V Charging voltage / checking the voltage regulator-rectifier NOTE: The values stated below apply only to fully charged batteries (minimum charging level 90%). Repair manual KTM LC4 – Start the engine and switch on the low beam. – Connect a voltmeter to both battery connections. – Accelerate the engine to a speed of 5000 rpm and read off the voltage. Nominal value: 14.0 - 15.0 V In the case of a significant deviation from the nominal value: – Check the connector between the stator and the voltage regulatorrectifier and the connector between the voltage regulator-rectifier and the cable tree. – Check the stator. – Replace the voltage regulator-rectifier. 7-7D Checking the capacitor – Pull main fuse out of the fuse holder. – Discharge the capacitor 1 by bridging the two terminals with a screwdriver and remove. – Connect the negative pole of a 12V battery with the negative terminal of the capacitor. The connection between the positive pole of the battery and the positive terminal of the capacitor (marked +) is made with a test lamp 3. – When the power circuit is closed, the test lamp must begin to light up. As capacitor charging increases, the brightness of the test lamp must decrease. – The test lamp must go out after 0,5-2 seconds (depending on the lamp capacity). – If the test lamp does not go out or does not light up at all, the capacitor is faulty. 3 ! ! CAUTION DISCHARGE THE CAPACITOR BEFORE AND AFTER EACH TEST. WHEN INSTALLING THE CAPACITOR, MAKE SURE THAT THE TERMINALS ARE CONNECTED IN ACCORDANCE WITH THEIR MARKINGS. CONNECT RED/WHITE CABLE TO + TERMINAL. Checking the neutral switch – Remove the chain cover. – Connect one terminal of a test lamp to the positive pole of the battery and the other to connection 1 of the neutral switch. – The test lamp must light up when the transmission is switched to neutral. – The test lamp must go out as soon as a gear is put in. 1 7-8D ELECTRICAL – LC4 CDI 2 ignition lock ge-r s-r 3 r-s ge start relay 5 4 Art.-Nr. 3.206.006 -E br bl . br . ge gr . g . o . r .. ra . s.. v . w . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .blue .brown .yellow .grey .green .orange .red .pink .black .violet .white Charging system 1 2 3 4 5 Generator Regulator-rectifier Main fuse (20 A) Battery (12V / 8 Ah) Capacitor Leakage inspection The drop test must be performed before checking the voltage regulator/rectifier – Turn off the ignition and disconnect the ground wire from the battery. – Insert an amperemeter between the ground wire and the negative pole of the battery. Repair manual KTM LC4 Setpoint value: max. 1 mA – Check for power consumers, should the measured value exceed the indicated maximum value. Example: ● defective voltage regulator-rectifier ● leak currents in the socket connectors, in the ignition lock or in the starter relay. 0,00 7-9D Removing the battery 1 – Remove the seat. – Disconnect first the negative and then the positive pole of the battery. – Remove the bolts 1 and swing the battery support with the voltage regulator-rectifier sideways. – Remove the battery. – When reinstalling the battery, connect the negative pole last. ! ! CAUTION FOLLOW THE INSTRUCTIONS OF THE MANUFACTURER WHEN FILLING A NEW BATTERY. THE RELEVANT SAFETY INSTRUCTIONS ARE ALSO CONTAINED IN THE USER MANUAL SUPPLIED WITH THE BATTERY. ANY FAILURE TO OBSERVE THESE INSTRUCTIONS MAY RESULT IN SEVERE INJURIES. Charging the battery – Remove the battery and check the charging level. Use a voltmeter to measure the voltage between the battery poles (off-load voltage). – Accurate results can only be obtained if the battery has neither been charged nor discharged during a period of 30 minutes preceding the measuring. – If the battery is empty, it can be recharged for a maximum period of 10 hours at 0.8 A and a maximum of 14.4 V. ! CAUTION ! – TO AVOID DAMAGE, DO NOT REMOVE THE LOCKING BAR. – ALWAYS CONNECT THE BATTERY TO THE CHARGING UNIT BEFORE TURNING THE CHARGING UNIT ON. – WHEN RECHARGING THE BATTERY IN CLOSED ROOMS ENSURE SUFFICIENT VENTILATION. EXPLOSIVE GASES ARE RELEASED DURING THE BATTERY CHARGING PROCESS. – CHARGING TIME AND CHARGING VOLTAGE SHOULD NOT EXCEED THE STATED VALUES. OTHERWISE ELECTROLYTE WILL BE RELEASED THROUGH THE SAFETY VALVES. – AVOID QUICK CHARGING IF POSSIBLE. off load voltage Volt charging level % charging time 0.8 A >12.7 ~12.5 ~12.2 ~12.0 ~11.8 100 75 50 25 0 –– 4h 7h 11 h 14 h charging voltage max. 14.4 V Charging voltage / checking the voltage regulator-rectifier NOTE: The values stated below apply only to fully charged batteries (minimum charging level 90%). – Start the engine and switch on the low beam. – Connect a voltmeter to both battery connections. – Accelerate the engine to a speed of 5000 rpm and read off the voltage. Nominal value: 14.0 - 15.0 V In the case of a significant deviation from the nominal value: – Check the connector between the stator and the voltage regulatorrectifier and the connector between the voltage regulator-rectifier and the cable tree. – Check the stator. – Replace the voltage regulator-rectifier. 7-10D Checking the capacitor – Pull main fuse out of the fuse holder. – Discharge the capacitor 1 by bridging the two terminals with a screwdriver and remove. – Connect the negative pole of a 12V battery with the negative terminal of the capacitor. The connection between the positive pole of the battery and the positive terminal of the capacitor (marked +) is made with a test lamp 1. – When the power circuit is closed, the test lamp must begin to light up. As capacitor charging increases, the brightness of the test lamp must decrease. – The test lamp must go out after 0,5-2 seconds (depending on the lamp capacity). – If the test lamp does not go out or does not light up at all, the capacitor is faulty. Repair manual KTM LC4 Art.-Nr. 3.206.006 -E 1 ! ! CAUTION DISCHARGE THE CAPACITOR BEFORE AND AFTER EACH TEST. WHEN INSTALLING THE CAPACITOR, MAKE SURE THAT THE TERMINALS ARE CONNECTED IN ACCORDANCE WITH THEIR MARKINGS. CONNECT RED/WHITE CABLE TO + TERMINAL. 7-11D ge-bl 10 A 3 ge-bl 2 ge-r r s 5 4 to EPC control unit o ge r-w bl-w 20 A 9 M 1 2 3 4 5 6 7 8 9 bl . br . ge gr . g . o . r .. ra . s.. v . w . Battery Ignition lock Emergency off switch Auxiliary relay Tip switch built in emergency off switch Neutral switch Clutch switch Starter relay Starter motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .blue .brown .yellow .grey .green .orange .red .pink .black .violet .white 6 br G 7 g-s 1 ge 8 Electric Starter system NOTE: The electric starter system is equipped with a safety mechanism. Starting is possible only in the following conditions: ● ignition lock in position or ● emergency OFF switch in position ● transmission set to idle, or clutch is pulled Function of the electric starter system: From the battery 1, battery voltage is supplied via the ignition lock 2 and the emergency OFF switch 3 to the coil of the auxiliary starter relay 4 and the tip switch 5. The contact of the auxiliary starter relay will enable starting only if at least one of the following conditions is met : ● transmission is set to idle (idle switch 6 closed) ● clutch is pulled (clutch switch 7 closed) If the tip switch 5 is actuated, the electric starter motor 9 is turned on by way of the starter relay 8. 7-12D Check start auxiliary relay – Remove headlight mask and remove the start auxiliary relay. 1 – Connect the start auxiliary relay to a 12 V battery as shown in the illustration. – Use an ohmmeter to measure the continuity between the terminals A and B. A Reading 0 Ω relay intact Reading ∞ Ω relay defect B Checking the auxiliary starting relay for faultless operation Art.-Nr. 3.206.006 -E Preparation: – Pull the auxiliary starter relay out of its holder. – Connect an ohmmeter or a continuity tester to the cables of the auxiliary starting relay (colors: red and red/white). – Perform the tests in the order indicated below. The auxiliary starting relay must respond in either of the following two cases: 2 ● Put in a gear and slowly pull the clutch lever. The auxiliary starting relay should respond when the lever is pulled approximately half of the overall distance. If this is not the case, please check the clutch switch. Keep an eye on the neutral control lamp while performing this test. The neutral control lamp should not light up. If it lights up, check the diode. ● Switch the transmission to neutral without previously pulling the clutch. The auxiliary starting relay should now connect and be tripped as soon as a gear is put in. If this is not the case, please check the diode and the neutral switch. Repair manual KTM LC4 NOTE: Connecting of the auxiliary starting relay is always accompanied by a faint clicking sound. The ohmmeter or continuity tester indicates continuity while the auxiliary starting relay is on. Checking the diode NOTE: Diodes conduct current only in the direction indicated by the arrow, preventing the conduction of current in the opposite direction. Two different kinds of diode defects can be distinguished: – The diode conducts no current at all. – The diode conducts current in both directions. Diode defects can lead to different kinds of trouble, depending on the type of defect. NOTE: The diode is located in a 2-pole connector. Checking for faultless operation: – Remove the headlight mask. – Pull the diode 2 out of the connector. – Connect an appropriate ohmmeter to the diode and check for continuity. – Connect the ohmmeter in the opposite direction and check if the diode prevents current conduction in the opposite direction. 7-13D Checking the starter relay – Remove the seat and the right side cover and disconnect the combination connector 1 of the starter relay. – Disconnect negative terminal at battery and the two cables at the starter relay. 1 C – Connect the starter relay to a 12 V battery as indicated in the diagram. – Check continuity between terminals C and D using an ohmmeter. Reading: 0 Ω OK Reading: ∞ Ω defect NOTE: The response of the starter relay is accompanied by a faint clicking sound. D Checking the electric starter motor 2 – Switch off the ignition. – Disconnect the negative pole of the battery and remove the electric starter motor. – Connect the negative pole of a 12 V battery to the housing of the E starter motor and briefly connect the positive pole of the battery to connection 2 of the electric starter motor (use thick cables). – The starter must turn as soon as the circuit is closed. – If this is not the case, replace the starter motor. 7-14D Checking the clutch switch – Disconnect the clutch switch from the cable tree. – Connect the ohmmeter to the 2-pole connector 2 (cable colors: yellow/yellow) of the clutch switch and slowly pull the clutch lever. – The switch must connect when the lever is pulled approximately half of the overall distance. 2 Checking the tip switch and the emergency OFF switch – Remove the headlight mask. – Disconnect the 4-pole connector 3 of the tip switch/emergency OFF switch from the cable tree. – Use an ohmmeter and test both switches according to the table below (please refer to the sketch for the configuration of the connector). – Then check all lines for ground contact. 3 Art.-Nr. 3.206.006 -E Circuit Emergency off switch Emergency off switch Tip switch Tip switch Position operated not operated Condition duct no duct duct no duct start switch emergenc y off switch Trouble shooting in the electric starter system Repair manual KTM LC4 When the starter motor fails to turn upon operation of the tip switch, perform the following checks first: ● ● ● ● ● ● ● ● Is the ignition lock in position or ? Is the emergency OFF switch position ? Is the neutral control lamp on while the ignition is on? Can the engine be started with the clutch pulled? Is the battery charged? Has the main fuse blown? Has the fuse for startsystem and ignition blown? Fuse for starter system and ignition has melted? ● Check the auxiliary starting relay ● Check the starter relay ● Check the electric starter motor 7-15D 3 4 to EPC-controlunit bl-w 2 6 s-r r-s 1 M s g w 8 G 7 1 2 3 4 5 6 7 8 bl . br . ge gr . g . o . r .. ra . s.. v . w . Battery Main fuse (20 A) Ignition lock Emergency-off switch Auxiliary relay CDI Pulse generator Ignition coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .blue .brown .yellow .grey .green .orange .red .pink .black .violet .white Ignition system From the battery 1, battery voltage is delivered via the main fuse 2, through the activated ignition lock 3 and the activated emergency OFF switch 4 to the CDI unit 6. During each revolution of the crankshaft, the pulse generator 7 supplies a signal to the CDI unit 6. In the CDI unit, this signal is processed so as to calculate the ignition point. This ignition pulse is passed on to the ignition coil 8 (the ignition spark is produced). The ignition system is a digital high voltage capacitor ignition that receives its power supply from the battery. Therefore, it works only with an intact battery. When the battery is discharged below the threshold level, the voltage can, due to the starting process, drop below the minimum supply voltage required by the ignition. In this case, turn off the light, and use the kickstarter. ! SAFE CAUTION ! AND FAULTLESS OPERATION OF THE DIGITAL IGNITION REQUIRES SPARK PLUG CONNECTORS AND SPARK PLUGS WITH INTEGRATED RESISTANCE TYPE SUPPRESSORS. 7-16D CDI unit Check the cables and plug and socket connections of the CDI unit 1. The CDI unit function can only be checked on an ignition test bench. ! CAUTION NEVER USE A COMMERCIAL MEASURING DEVICE COMMERCIAL MEASURING DEVICES CAN DESTROY COMPONENTS. ! TO CHECK THE CDI UNIT. HIGHLY SENSITIVE ELECTRONIC 1 Checking the ignition coil 2 – Disconnect all cables and remove the spark plug connector. – Use an ohmmeter to measure the following values. NOTE: The indicated setpoint values correspond to a temperature of 20° C. Replace the ignition coil if the measured values deviate significantly from the setpoint values. MEASUREMENT COLOURS RESISTANCE primary coil blue/white – ground 0,425 – 0,575 Ω secondary coil blue/white – ignition wire 10,80 – 16,20 kΩ Trouble shooting in the ignition system Art.-Nr. 3.206.006 -E Before checking the ignition system check: ● ● ● ● ● ● if the ignition lock is in position or if the emergency off switch is in position if the neutral control lamp is on if the motorcycle can be started with the clutch pulled if the battery is charged the main fuse Repair manual KTM LC4 Check if an ignition spark is produced when the starter is operated. Proceed as follows: – Pull off the spark plug connector. – Disconnect the spark plug connector from the ignition cable. – Hold the free end of the ignition cable approximately 5 mm from ground. – A strong spark should be visible when the electric starter is now operated. If the battery level is low, turn off the light, and use the kick starter. – If a spark is visible, replace the spark plug connector. – Twist out the spark plug and insert it into the spark plug connector. – Connect the spark plug to ground. A strong spark should be visible at the electrode when the electric starter is now operated. If this is not the case, the spark plug connector or the spark plug is defect. – If no spark is produced during the first test, perform the following checks: ● Does the ignitionís power supply line (orange) carry battery voltage? ● If this is not the case, check the ignition lock, the emergency OFF switch and, if applicable, the side stand relay as well as the corresponding parts of the cable tree. – If the ignition is sufficiently supplied with power and no spark is produced, check: ● ground connection of CDI unit and ignition coil ● the cable between CDI unit and ignition coil ● pulse generator ● stator ● ignition coil NOTE: The CDI unit can’t be tested with simple devices. It can only be replaced. It can only be tested on an ignition test bench. 7-17D 4 10 3 5 ge-bl g-r r-s s-o bl-s 2 1 bl-w br 6 8 9 br 7 1 2 3 4 5 6 7 8 9 bk bl . br . ge gr . g . o . r .. ra . s.. v . w . Battery (12V / 8 Ah) Main fuse (20 A) Ignition lock Fuse for ignition and start system EPC-control unit Ignition lock Contact screw 2nd gear Contact screw 3rd gear Micro switch Solenoid valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .blue .brown .yellow .grey .green .orange .red .pink .black .violet .white EPC system Function: From the battery 1, battery voltage is supplied to the EPC controller 5 via the main fuse 2, the activated ignition lock 3, and the fuse 4. The blue/white cable leading to the ignition coil 6 provides an r.p.m. signal to the EPC controller 5. Using this signal, the EPC controller will then calculate the current speed. When the throttle grip is opened all the way (microswitch 9 closes) at a certain speed, the EPC controller will activate the solenoid valve bk, provided that either the 2nd or the 3rd gear has been engaged. By opening the solenoid valve bk, a dosed amount of fresh air will get to the upper end of the slide membranes of the carburetor. This causes the throttle slide to open slowly. Thereby, the operating noise of the motorbike is reduced. NOTE: If malfunctions develop in the EPC system, the EPC controller can be unplugged. This will not cause damage to any other parts of the motorcycle. 7-18D Dismount / renew solenoid valve for EPC – Remove seat, side covers, and tank with spoilers. – Unplug the solenoid-valve connector. – Disconnect the two hoses, and pull solenoid valve 1 upwards and out of the holder. 1 – Insert new solenoid valve into the holder. – Connect the two hoses, and plug in connector. Check of solenoid valve for EPC NOTE: When you turn on the ignition, the solenoid valve must open for approx. 1 second. During this process, you can hear a slight clicking noise. – For checking, disconnect the 2-pole connector 2 at the solenoid valve. – Now, connect a 12V battery to both terminals of the solenoid valve. – When closing the power circuit, a clicking noise must be audible in the solenoid valve (the membrane opens). 2 – If you cannot hear any clicking noise, you have to replace the solenoid valve. Art.-Nr. 3.206.006 -E Controller of the EPC system NOTE: The controller 3 cannot be checked by means of standard measuring methods. 3 If malfunctions develop in the EPC system, start by checking: solenoid valve microswitch plug-and-socket connection 4 and cables contact screws at engine hose from magnetic valve to carburetor – If the above components are okay, the controller has to be replaced. ! BEFORE CAUTION ! Repair manual KTM LC4 CONNECTING THE CONTROLLER, IT IS ABSOLUTELY NECESSARY THAT YOU TURN OFF THE IGNITION. OTHERWISE, MALFUNCTIONS IN THE ELECTRONIC SYSTEM MAY DEVELOP. 4 7-19D Check of EPC system microswitch NOTE: The microswitch is arranged on the left side of the constantdepression carburetor in the area of the throttle valve. If the throttle valve is opened all the way, the microswitch will close the power circuit. – Remove seat and tank. – Disconnect the 2-pole plug 2 of the microswitch. – Connect an ohmmeter to both terminals of the microswitch. – With the throttle valve closed, the ohmmeter must indicate zero continuity. – Open throttle valve all the way by twisting the throttle grip as far as possible. In this case, you will hear a slight clicking noise of the microswitch. In this position, the ohmmeter must indicate conductive continuity. 2 Replacing the EPC system microswitch – Remove seat and tank. – Disconnect the microswitch plug. – Remove the 2 screws 3, and take off the microswitch. – Apply Loctite 243 to the threads of the two screws. – Position the new microswitch, and fasten it with the two screws. – Connect the plug, mount tank and seat. 3 Check of idle switch / contact screws NOTE: The contact screw having the cable colors black/blue closes the contact, when the 2nd gear is engaged. The contact screw having the cable colors black/orange closes the contact, when the 3rd gear is engaged. The contact screw having the cable colors black/green closes the contact, when the idle gear is engaged. 1 – Before you start with the check, disconnect the plug-and-socket connection 1 to the EPC controller. – For checking of the contact screws, connect a test lamp to the positive terminal of the battery. – Touch the connection of the central contact screw 6 with the test probe. With the transmission set to idle, the test lamp has to be lit. – When a gear is engaged, the test lamp must cease to be lit. 6 4 – Shift to 2nd gear, and touch the connection of the lower contact screw 5 with the test probe. The test lamp must light up. – With the transmission set to idle, the test lamp must not be lit. – Shift to 3rd gear, and touch the connection of the upper contact screw 4 with the test probe. The test lamp must light up. – With the transmission set to idle, the test lamp must not be lit. 5 7-20D ELECTRICAL – DUKE-E CDI 2 ignition lock ge-r 1 3 s-r start relay r-s ge ge 5 4 tachometer Art.-Nr. 3.206.006 -E br bl . br . ge gr . g . o . r .. ra . s.. v . w . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .blue .brown .yellow .grey .green .orange .red .pink .black .violet .white Charging system Repair manual KTM LC4 1 2 3 4 5 Generator Regulator-rectifier Main fuse (20 A) Battery (12V / 8 Ah) Capacitor Leakage inspection The drop test must be performed before checking the voltage regulator/rectifier – Turn off the ignition and disconnect the ground wire from the battery. – Insert an amperemeter between the ground wire and the negative pole of the battery. Setpoint value: max. 1 mA 0,00 – Check for power consumers, should the measured value exceed the indicated maximum value. Example: ● defective voltage regulator-rectifier ● leak currents in the socket connectors, in the ignition lock or in the starter relay. 7-21D Charging voltage / checking the voltage regulator-rectifier NOTE: The values stated below apply only to fully charged batteries (minimum charging level 90 %). – Start the engine and switch on the low beam. – Connect a voltmeter to both battery connections. – Accelerate the engine to a speed of 5000 rpm and read off the voltage. Nominal value: 14.0 - 15.0 V In the case of a significant deviation from the nominal value: – Check the connector between the stator and the voltage regulatorrectifier and the connector between the voltage regulator-rectifier and the cable tree. – Check the stator. – Replace the voltage regulator-rectifier. Removing the battery 1 1 – Remove the seat. – Disconnect first the negative and then the positive pole of the battery. – Remove the bolts 1 and swing the battery support with the voltage regulator-rectifier sideways. – Remove the battery. – When reinstalling the battery, connect the negative pole last. ! CAUTION ! FOLLOW THE INSTRUCTIONS OF THE MANUFACTURER WHEN FILLING A NEW THE RELEVANT SAFETY INSTRUCTIONS ARE ALSO CONTAINED IN THE USER SUPPLIED WITH THE BATTERY. BATTERY. MANUAL Charging the battery – Remove the battery and check the charging level. Use a voltmeter to measure the voltage between the battery poles (off-load voltage). – Accurate results can only be obtained if the battery has neither been charged nor discharged during a period of 30 minutes preceding the measuring. – If the battery is empty, it can be recharged for a maximum period of 10 hours at 0.8 A and a maximum of 14.4 V. ! CAUTION ! – TO AVOID DAMAGE, DO NOT REMOVE THE LOCKING BAR – ALWAYS CONNECT THE BATTERY TO THE CHARGING UNIT BEFORE TURNING THE CHARGING UNIT ON. – WHEN RECHARGING THE BATTERY IN CLOSED ROOMS ENSURE SUFFICIENT VENTILATION. EXPLOSIVE GASES ARE RELEASED DURING THE BATTERY CHARGING PROCESS. – CHARGING TIME AND CHARGING VOLTAGE SHOULD NOT EXCEED THE STATED VALUES. OTHERWISE ELECTROLYTE WILL BE RELEASED THROUGH THE SAFETY VALVES. – AVOID QUICK CHARGING IF POSSIBLE. off load voltage Volt charging level % charging time 0.8 A >12.7 ~12.5 ~12.2 ~12.0 ~11.8 100 75 50 25 0 –– 4h 7h 11 h 14 h charging voltage max. 14.4 V 7-22D Checking the capacitor – Pull main fuse out of the fuse holder. – Discharge the capacitor by bridging the two terminals with a screwdriver and remove. – Connect the negative pole of a 12V battery with the negative terminal of the capacitor. The connection between the positive pole of the battery and the positive terminal of the capacitor (marked +) is made with a test lamp 1. – When the power circuit is closed, the test lamp must begin to light up. As capacitor charging increases, the brightness of the test lamp must decrease. – The test lamp must go out after 0,5-2 seconds (depending on the lamp capacity). – If the test lamp does not go out or does not light up at all, the capacitor is faulty. Repair manual KTM LC4 Art.-Nr. 3.206.006 -E 1 ! ! CAUTION DISCHARGE THE CAPACITOR BEFORE AND AFTER EACH TEST. WHEN INSTALLING THE CAPACITOR, MAKE SURE THAT THE TERMINALS ARE CONNECTED IN ACCORDANCE WITH THEIR MARKINGS. CONNECT RED/WHITE CABLE TO + TERMINAL. 7-23D ge-bl 3 ge-bl 2 ge-r s r 5 ge r-w 4 ge 1 9 M 1 2 3 4 5 6 7 8 9 bl . br . ge gr . g . o . r .. ra . s.. v . w . Battery Ignition lock Emergency off switch Auxiliary relay Tip switch built in emergency off switch Neutral switch Clutch switch Start relay Starter motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .blue .brown .yellow .grey .green .orange .red .pink .black .violet .white 6 br G 7 g-s 8 Electric starter system The system is equipped with a safety mechanism. Electric starting is only possible when ● the ignition lock is in the position ● the emergency OFF switch is in the position ● the transmission is switched to neutral or the clutch is pulled. Function of the electric starter system: From the battery 1 the battery voltage is transmitted via the ignition lock 2 and the emergency OFF switch 3 to the coil of the auxiliary starting relay 4 and to the tip switch 5. The contact of the auxiliary starting relay prevents starting unless at least one of the following requirements is met : ● The transmission must be switched to neutral (neutral switch 6 is closed). ● The clutch must be pulled (clutch switch 7 must be closed). When the tip switch 5 is operated, the starter motor 9 is switched on via the starter relay 8. 7-24D Check start auxiliary relay – Remove headlight mask and remove the start auxiliary relay (cable colours red and red-white). A B – Connect the start auxiliary relay to a 12 V battery as shown in the illustration. – Use an ohmmeter to measure the continuity between the terminals A and B. Reading 0 Ω relay intact Reading ∞ Ω relay defect Art.-Nr. 3.206.006 -E Checking the auxiliary starting relay for faultless operation Preparation: – Connect an ohmmeter or a continuity tester to the cables of the auxiliary starting relay (colors: red and red/white). – Perform the tests in the order indicated below. The auxiliary starting relay must respond in either of the following two cases: ● Put in a gear and slowly pull the clutch lever. The auxiliary starting relay should respond when the lever is pulled approximately half of the overall distance. If this is not the case, please check the clutch switch. Keep an eye on the neutral control lamp while performing this test. The neutral control lamp should not light up. If it lights up, check the diode with the cable colors yellow and green/black. ● Switch the transmission to neutral without previously pulling the clutch. The auxiliary starting relay should now connect and be tripped as soon as a gear is put in. If this is not the case, please check the diode in the connector with the cable colors yellow and green/black and the neutral switch. Repair manual KTM LC4 NOTE: Connecting of the auxiliary starting relay is always accompanied by a faint clicking sound. The ohmmeter or continuity tester indicates continuity while the auxiliary starting relay is on. 7-25D Checking the diodes NOTE: Diodes conduct current only in the direction indicated by the arrow, preventing the conduction of current in the opposite direction. Two different kinds of diode defects can be distinguished: – The diode conducts no current at all. – The diode conducts current in both directions. Diode defects can lead to different kinds of trouble, depending on the type of defect. NOTE: Both diodes are the same type and require the same testing procedure. They are each located in a 2-pole connector and can be identified by the color of the cables leading up to and away from the respective connector. Checking the diodes for faultless operation: – Remove the headlight mask. – Pull the diode to be tested out of the connector. – Connect an appropriate ohmmeter to the diode and check for continuity. – Connect the ohmmeter in the opposite direction and check if the diode prevents current conduction in the opposite direction. Checking the clutch switch – Disconnect the clutch switch from the cable tree. – Connect the ohmmeter to the 2-pole connector 3 (cable colors: yellow/yellow) of the clutch switch and slowly pull the clutch lever. – The switch must connect when the lever is pulled approximately half of the overall distance. 3 Checking the tip switch and the emergency off switch – Remove the headlight mask. – Disconnect the 4-pole connector 4 of the tip switch/emergency OFF switch from the cable tree. – Use an ohmmeter and test both switches according to the table below (please refer to the sketch for the configuration of the connector). – Then check all lines for ground contact. Circuit Emergency off switch Emergency off switch Tip switch Tip switch 4 starter tip switch emergenc y off switch Position operated not operated Condition duct no duct duct no duct 7-26D Checking the starter relay – Remove the seat and the right side cover and disconnect the combination connector 1 of the starter relay. – Disconnect negative terminal at battery and the two cables at the starter relay. 1 – Connect the starter relay to a 12 V battery as indicated in the diagram. – Check continuity between terminals C and D using an ohmmeter. C Reading: 0 Ω OK Reading: ∞ Ω defect NOTE: The response of the starter relay is accompanied by a faint clicking sound. D Art.-Nr. 3.206.006 -E Checking the electric starter motor – Switch off the ignition. – Disconnect the negative pole of the battery and remove the electric starter motor. – Connect the negative pole of a 12 V battery to the housing of the E starter motor and briefly connect the positive pole of the battery to connection 2 of the electric starter motor (use thick cables). – The starter must turn as soon as the circuit is closed. – If this is not the case, replace the starter. 2 Checking the neutral switch Repair manual KTM LC4 – Remove the chain cover. – Connect one terminal of a test lamp to the positive pole of the battery and the other to connection 3 of the neutral switch. – The test lamp must light up when the transmission is switched to neutral. – The test lamp must go out as soon as a gear is put in. 3 Trouble shooting in the electric starter system When the starter motor fails to turn upon operation of the tip switch, perform the following checks first: ● ● ● ● ● ● Is the ignition lock switched to ? Is the emergency OFF switch in the position ? Is the neutral control lamp on while the ignition is on? Can the engine be started with the clutch pulled? Is the battery charged? Has the main fuse blown? ● Check the auxiliary starting relay ● Check the starter relay ● Check the starter motor 7-27D ge-bl 4 r 3 5 2 0 ra s-r r ra 6 1 8 s g w ge r-s 9 M G 7 1 2 3 4 5 6 7 8 9 Battery Main fuse Ignition lock Emergency-off switch Auxiliary relay CDI Pulse generator Ignition coil Side stand switch Ignition system From the battery 1 the battery voltage is conducted via the main fuse 2 through the ignition lock 3 and the emergency OFF switch 4, which are both ON, to the side stand relay 5. The side stand relay conducts the battery voltage to the CDI unit 6, if at least one of the following requirements is met : ● The side stand is up (side stand switch closed). ● The transmission is switched to neutral (neutral switch closed). ● The clutch is pulled (clutch switch closed). The pulse generator 7 transmits a signal to the CDI unit 6 upon every rotation of the crankshaft. In the CDI unit, the ignition point is computed from this signal. The ignition pulse is transmitted to the ignition coil 8 (i.e. an ignition spark is generated). bl . br . ge gr . g . o . r .. ra . s.. v . w . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .blue .brown .yellow .grey .green .orange .red .pink .black .violet .white NOTE: The ignition system is a digital high voltage capacitor ignition that receives its power supply from the battery. Therefore, it works only with an intact battery. When the battery is discharged below the threshold level, the voltage can, due to the starting process, drop below the minimum supply voltage required by the ignition. ! SAFE CAUTION ! AND FAULTLESS OPERATION OF THE DIGITAL IGNITION REQUIRES SPARK PLUG CONNECTORS AND SPARK PLUGS WITH INTEGRATED RESISTANCE TYPE SUPPRESSORS. 7-28D CDI unit Check the cables and plug and socket connections of the CDI unit 1. The CDI unit function can only be checked on an ignition test bench. ! CAUTION NEVER USE A COMMERCIAL MEASURING DEVICE COMMERCIAL MEASURING DEVICES CAN DESTROY COMPONENTS. ! TO CHECK THE CDI UNIT. HIGHLY SENSITIVE ELECTRONIC 1 Check ignition coil – Disconnect all cables and remove the spark plug connector. – Use an ohmmeter to measure the following values. NOTE: The indicated setpoint values correspond to a temperature of 20° C. Replace the ignition coil if the measured values deviate significantly from the setpoint values. MEASUREMENT COLOURS RESISTANCE primary coil blue/white – ground 0,425 – 0,575 Ω secondary coil blue/white – ignition wire 10,80 – 16,20 kΩ Spark plug connector Art.-Nr. 3.206.006 -E – Check the spark plug connector for cracks and fissures. – Measure spark plug connector resistance. Setpoint value: 3.0 – 7.5 kΩ Checking the side stand relay Repair manual KTM LC4 Preparation: – Remove the seat, the right side cover and the headlight mask. – Disconnect the power supply from the CDI (orange cable). – To check the current status of the relay connect the orange cable coming from the cable tree either to the positive line of a voltmeter or to a test lamp. – The negative line of the voltmeter or test lamp is connected to ground. – Switch on the ignition lock and the emergency OFF switch. 2 Perform the following tests in the order indicated below: – The relay must connect in either of the following three cases: ● Put a gear in but do not pull the clutch. Slowly swing up the side stand. When the side stand is approximately halfway up, the side stand relay should respond. If this is not the case, please check the relay, the side stand switch 2 as well as the corresponding parts of the cable tree. ● With the side stand down and a gear put in, slowly pull the clutch lever. The side stand relay should respond when the lever is pulled approximately half of the overall distance. If this is not the case, please check the diode in the connector with the yellow and the pink cable and the neutral switch. ● With the side stand down and the clutch not pulled, switch the transmission to neutral. The relay should connect when the transmission is switched to neutral and be tripped when a gear is put in. If this is not the case, please check the diode in the connector with the yellow and the green/black cable and the neutral switch. NOTE: Responding of the relay is accompanied by a faint clicking sound and the CDI’s power supply is switched on. The voltmeter or the test lamp indicates a battery voltage. After testing, reconnect the CDI unit’s power supply (orange cable). 7-29D Checking the side stand switch 2 – Disconnect the 2 connectors connecting the side stand switch 2 with the cable tree (below the tank). – Connect an ohmmeter to the side stand cable. – Slowly swing up the side stand. – The switch must be open while the side stand is down. – The side stand switch must connect when the side stand is approximately halfway up. – If this is not the case, replace the side stand switch. ! CAUTION NEVER SHORT-CIRCUIT THE SIDE STAND SWITCH SO AS TO BE THIS WOULD DEACTIVATE THE IGNITION CUT-OFF WITH THE ! ABLE TO DRIVE ON. SIDE STAND DOWN, AND YOUR MOTORCYCLE WOULD NO LONGER COMPLY WITH THE APPLICABLE SAFETY STANDARDS. NOTE: If the side stand is removed, for example when subsequently installing a center stand, the two connectors of the cable tree that lead to the side stand switch must also be connected. Trouble shooting in the ignition system Before checking the ignition system check ● if the ignition lock is in position ● if the emergency off switch is in the position ● if the neutral control lamp is on ● if the motorcycle can be started with the clutch pulled ● if the battery is charged ● the main fuse Check if an ignition spark is produced when the starter is operated. Proceed as follows: – Pull the spark plug connector. – Disconnect the spark plug connector from the ignition cable. – Hold the free end of the ignition cable approximately 5 mm from ground. – A strong spark should be visible when the electric starter is now operated. If the battery is discharged below the threshold level required for electric starting, please use the kickstarter. – If a spark is visible, replace the spark plug connector. – Twist out the spark plug and insert it into the spark plug connector. – Connect the spark plug to ground. A strong spark should be visible at the electrode when the electric starter is now operated. If this is not the case, the spark plug connector or the spark plug is defect. – If no spark is produced during the first test, perform the following checks: ● Does the ignition’s power supply line (orange) carry battery voltage? ● If this is not the case, check the ignition lock, the emergency off switch and, if applicable, the side stand relay as well as the corresponding parts of the cable tree. – If the ignition is sufficiently supplied with power and no spark is produced, check: ● ground connection of CDI unit and ignition coil ● the cable between CDI unit and ignition coil ● pulse generator ● stator ● ignition coil 7-30D ELECTRICAL – SXC ‘99 Checking the voltage regulator-rectifier – Start the engine and switch on the low beam. – Connect a voltmeter to the two terminals of the capacitor (red/white cable = positive, brown cable = negative). – Accelerate the engine to a speed of 5000 r.p.m. and read off the voltage. Nominal value: 14.0 - 15.0 V If the reading significantly deviates from the nominal value above, check the capacitor. If the capacitor is intact, replace the voltage regulator-rectifier. Checking the capacitor Repair manual KTM LC4 Art Nr 320549-D 3 – Discharge the capacitor by bridging the two terminals with a screwdriver and remove. – Connect the negative pole of a 12V battery with the negative terminal of the capacitor. The connection between the positive pole of the battery and the positive terminal of the capacitor (marked +) is made with a test lamp 3. – When the power circuit is closed, the test lamp must begin to light up. As capacitor charging increases, the brightness of the test lamp must decrease. – The test lamp must go out after 0,5-2 seconds (depending on the lamp capacity). – If the test lamp does not go out or does not light up at all, the capacitor is faulty. ! CAUTION ! DISCHARGE THE CAPACITOR BEFORE AND AFTER EACH TEST. WHEN INSTALLING THE CAPACITOR, MAKE SURE THAT THE TERMINALS ARE CONNECTED IN ACCORDANCE WITH THEIR MARKINGS. CONNECT RED/WHITE CABLE TO + TERMINAL. 7-30 ELECTRICAL – SC ‘99 Checking the voltage regulator (Kokusan) A defect voltage regulator can cause different kinds of trouble: ● No voltage in the circuit In this case, the voltage regulator must be disconnected at idle speed. The voltage regulator is defect if the power consumers now work properly. If the power consumers are still not supplied with power, the switch, the wiring harness or the ignition system must be checked for defects. ● Excessive voltage in the circuit The bulbs burn out. In this case the voltage regulator must be replaced. Checking the capacitor – Discharge the capacitor 1 by bridging the two terminals with a screwdriver and remove. – Connect the negative pole of a 12V battery with the negative terminal of the capacitor. The connection between the positive pole of the battery and the positive terminal of the capacitor (marked +) is made with a test lamp 3. – When the power circuit is closed, the test lamp must begin to light up. As capacitor charging increases, the brightness of the test lamp must decrease. – The test lamp must go out after 0,5-2 seconds (depending on the lamp capacity). – If the test lamp does not go out or does not light up at all, the capacitor is faulty. ! CAUTION ! DISCHARGE THE CAPACITOR BEFORE AND AFTER WHEN INSTALLING THE CAPACITOR, MAKE 3 EACH TEST. SURE THAT THE TERMINALS ARE CONNECTED IN ACCORDANCE WITH THEIR MARKINGS. CONNECT RED/WHITE CABLE TO + TERMINAL. Check ignition coil – Disconnect all cables and remove the spark plug connector. – Use an ohmmeter to measure the following values. NOTE: The indicated setpoint values correspond to a temperature of 20° C. Replace the ignition coil if the measured values deviate significantly from the setpoint values. MEASUREMENT COLOURS RESISTANCE primary coil blue/white – ground 0,425 – 0,575 Ω secondary coil blue/white – ignition wire 10,80 – 16,20 kΩ 7-32D ELECTRICAL – DUKE ‘99 CDI 2 ignition lock ge-r 1 3 s-r start relay r-s ge ge 5 4 tachometer Art.-Nr. 3.206.006 -E br bl . br . ge gr . g . o . r .. ra . s.. v . w . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .blue .brown .yellow .grey .green .orange .red .pink .black .violet .white Charging system 1 2 3 4 5 Generator Regulator-rectifier Main fuse (20 A) Battery (12V / 8 Ah) Capacitor Leakage inspection The drop test must be performed before checking the voltage regulator/rectifier. – Turn off the ignition and disconnect the ground wire from the battery. – Insert an amperemeter between the ground wire and the negative pole of the battery. Repair manual KTM LC4 Setpoint value: max. 1 mA – Check for power consumers, should the measured value exceed the indicated maximum value. Example: ● defective voltage regulator-rectifier ● leak currents in the socket connectors, in the ignition lock or in the starter relay. 0,00 7-33D Charging voltage / checking the voltage regulator-rectifier NOTE: The values stated below apply only to fully charged batteries (minimum charging level 90 %). – Start the engine and switch on the low beam. – Connect a voltmeter to both battery connections. – Accelerate the engine to a speed of 5000 rpm and read off the voltage. Nominal value: 14.0 - 15.0 V In the case of a significant deviation from the nominal value: – Check the connector between the stator and the voltage regulatorrectifier and the connector between the voltage regulator-rectifier and the cable tree. – Check the stator. – Replace the voltage regulator-rectifier. Removing the battery – Remove the seat. – Disconnect first the negative and then the positive pole of the battery. – Remove the bolts 1 and swing the battery support with the voltage regulator-rectifier sideways. – Remove the battery. – When reinstalling the battery, connect the negative pole last. 1 ! CAUTION ! FOLLOW THE INSTRUCTIONS OF THE MANUFACTURER WHEN FILLING A NEW THE RELEVANT SAFETY INSTRUCTIONS ARE ALSO CONTAINED IN THE USER SUPPLIED WITH THE BATTERY. BATTERY. MANUAL Charging the battery – Remove the battery and check the charging level. Use a voltmeter to measure the voltage between the battery poles (off-load voltage). – Accurate results can only be obtained if the battery has neither been charged nor discharged during a period of 30 minutes preceding the measuring. – If the battery is empty, it can be recharged for a maximum period of 10 hours at 0.8 A and a maximum of 14.4 V. ! CAUTION ! – TO AVOID DAMAGE, DO NOT REMOVE THE LOCKING BAR – ALWAYS CONNECT THE BATTERY TO THE CHARGING UNIT BEFORE TURNING THE CHARGING UNIT ON. – WHEN RECHARGING THE BATTERY IN CLOSED ROOMS ENSURE SUFFICIENT VENTILATION. EXPLOSIVE GASES ARE RELEASED DURING THE BATTERY CHARGING PROCESS. – CHARGING TIME AND CHARGING VOLTAGE SHOULD NOT EXCEED THE STATED VALUES. OTHERWISE ELECTROLYTE WILL BE RELEASED THROUGH THE SAFETY VALVES. – AVOID QUICK CHARGING IF POSSIBLE. off load voltage Volt charging level % charging time 0.8 A >12.7 ~12.5 ~12.2 ~12.0 ~11.8 100 75 50 25 0 –– 4h 7h 11 h 14 h charging voltage max. 14.4 V 7-34D Checking the capacitor – Pull main fuse out of the fuse holder. – Discharge the capacitor by bridging the two terminals with a screwdriver and remove. – Connect the negative pole of a 12V battery with the negative terminal of the capacitor. The connection between the positive pole of the battery and the positive terminal of the capacitor (marked +) is made with a test lamp 1. – When the power circuit is closed, the test lamp must begin to light up. As capacitor charging increases, the brightness of the test lamp must decrease. – The test lamp must go out after 0,5-2 seconds (depending on the lamp capacity). – If the test lamp does not go out or does not light up at all, the capacitor is faulty. Repair manual KTM LC4 Art.-Nr. 3.206.006 -E 1 ! ! CAUTION DISCHARGE THE CAPACITOR BEFORE AND AFTER EACH TEST. WHEN INSTALLING THE CAPACITOR, MAKE SURE THAT THE TERMINALS ARE CONNECTED IN ACCORDANCE WITH THEIR MARKINGS. CONNECT RED/WHITE CABLE TO + TERMINAL. 7-35D ge-bl 3 ge-bl 2 ge-r s r 5 ge r-w 4 ge 1 9 M 1 2 3 4 5 6 7 8 9 bl . br . ge gr . g . o . r .. ra . s.. v . w . Battery Ignition lock Emergency off switch Auxiliary relay Tip switch built in emergency off switch Neutral switch Clutch switch Start relay Starter motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .blue .brown .yellow .grey .green .orange .red .pink .black .violet .white 6 br G 7 g-s 8 Electric starter system The system is equipped with a safety mechanism. Electric starting is only possible when ● the ignition lock is in the position ● the emergency OFF switch is in the position ● the transmission is switched to neutral or the clutch is pulled. Function of the electric starter system: From the battery 1 the battery voltage is transmitted via the ignition lock 2 and the emergency OFF switch 3 to the coil of the auxiliary starting relay 4 and to the tip switch 5. The contact of the auxiliary starting relay prevents starting unless at least one of the following requirements is met : ● The transmission must be switched to neutral (neutral switch 6 is closed). ● The clutch must be pulled (clutch switch 7 must be closed). When the tip switch 5 is operated, the starter motor 9 is switched on via the starter relay 8. 7-36D Check start auxiliary relay – Remove headlight mask and remove the start auxiliary relay (cable colours red and red-white). A B – Connect the start auxiliary relay to a 12 V battery as shown in the illustration. – Use an ohmmeter to measure the continuity between the terminals A and B. Reading 0 Ω relay intact Reading ∞ Ω relay defect Art.-Nr. 3.206.006 -E Checking the auxiliary starting relay for faultless operation Preparation: – Connect an ohmmeter or a continuity tester to the cables of the auxiliary starting relay (colors: red and red/white). – Perform the tests in the order indicated below. The auxiliary starting relay must respond in either of the following two cases: ● Put in a gear and slowly pull the clutch lever. The auxiliary starting relay should respond when the lever is pulled approximately half of the overall distance. If this is not the case, please check the clutch switch. Keep an eye on the neutral control lamp while performing this test. The neutral control lamp should not light up. If it lights up, check the diode with the cable colors yellow and green/black. ● Switch the transmission to neutral without previously pulling the clutch. The auxiliary starting relay should now connect and be tripped as soon as a gear is put in. If this is not the case, please check the diode in the connector with the cable colors yellow and green/black and the neutral switch. Repair manual KTM LC4 NOTE: Connecting of the auxiliary starting relay is always accompanied by a faint clicking sound. The ohmmeter or continuity tester indicates continuity while the auxiliary starting relay is on. 7-37D Checking the diodes NOTE: Diodes conduct current only in the direction indicated by the arrow, preventing the conduction of current in the opposite direction. Two different kinds of diode defects can be distinguished: – The diode conducts no current at all. – The diode conducts current in both directions. Diode defects can lead to different kinds of trouble, depending on the type of defect. NOTE: Both diodes are the same type and require the same testing procedure. They are each located in a 2-pole connector and can be identified by the color of the cables leading up to and away from the respective connector. Checking the diodes for faultless operation: – Remove the headlight mask. – Pull the diode to be tested out of the connector. – Connect an appropriate ohmmeter to the diode and check for continuity. – Connect the ohmmeter in the opposite direction and check if the diode prevents current conduction in the opposite direction. Checking the clutch switch – Disconnect the clutch switch from the cable tree. – Connect the ohmmeter to the 2-pole connector 3 (cable colors: yellow/yellow) of the clutch switch and slowly pull the clutch lever. – The switch must connect when the lever is pulled approximately half of the overall distance. 3 Checking the tip switch and the emergency off switch – Remove the headlight mask. – Disconnect the 4-pole connector 4 of the tip switch/emergency OFF switch from the cable tree. – Use an ohmmeter and test both switches according to the table below (please refer to the sketch for the configuration of the connector). – Then check all lines for ground contact. 4 Circuit Emergency off switch Emergency off switch Tip switch Tip switch starter tip switch emergenc y off switch Position operated not operated Condition duct no duct duct no duct 7-38D Checking the starter relay – Remove the seat and disconnect the combination connector 1 of the starter relay. – Disconnect negative terminal at battery and the two cables at the starter relay. 1 – Connect the starter relay to a 12 V battery as indicated in the diagram. – Check continuity between terminals C and D using an ohmmeter. C Reading: 0 Ω OK Reading: ∞ Ω defect NOTE: The response of the starter relay is accompanied by a faint clicking sound. D Art.-Nr. 3.206.006 -E Checking the electric starter motor – Switch off the ignition. – Disconnect the negative pole of the battery and remove the electric starter motor. – Connect the negative pole of a 12 V battery to the housing of the E starter motor and briefly connect the positive pole of the battery to connection 2 of the electric starter motor (use thick cables). – The starter must turn as soon as the circuit is closed. – If this is not the case, replace the starter. 2 Checking the neutral switch Repair manual KTM LC4 – Remove the chain cover. – Connect one terminal of a test lamp to the positive pole of the battery and the other to connection 3 of the neutral switch. – The test lamp must light up when the transmission is switched to neutral. – The test lamp must go out as soon as a gear is put in. 3 Trouble shooting in the electric starter system When the starter motor fails to turn upon operation of the tip switch, perform the following checks first: ● ● ● ● ● ● ● Is the ignition lock switched to ? Is the emergency OFF switch in the position ? Is the neutral control lamp on while the ignition is on? Can the engine be started with the clutch pulled? Is the battery charged? Has the main fuse blown? Has the fuse under headlight mask blown? ● Check the auxiliary starting relay ● Check the starter relay ● Check the starter motor 7-39D ge-bl 4 r 3 5 2 0 ra s-r r ra 6 1 8 s g w ge r-s 9 M G 7 1 2 3 4 5 6 7 8 9 Battery Main fuse Ignition lock Emergency-off switch Auxiliary relay CDI Pulse generator Ignition coil Side stand switch Ignition system From the battery 1 the battery voltage is conducted via the main fuse 2 through the ignition lock 3 and the emergency OFF switch 4, which are both ON, to the side stand relay 5. The side stand relay conducts the battery voltage to the CDI unit 6, if at least one of the following requirements is met : ● The side stand is up (side stand switch closed). ● The transmission is switched to neutral (neutral switch closed). ● The clutch is pulled (clutch switch closed). The pulse generator 7 transmits a signal to the CDI unit 6 upon every rotation of the crankshaft. In the CDI unit, the ignition point is computed from this signal. The ignition pulse is transmitted to the ignition coil 8 (i.e. an ignition spark is generated). bl . br . ge gr . g . o . r .. ra . s.. v . w . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .blue .brown .yellow .grey .green .orange .red .pink .black .violet .white NOTE: The ignition system is a digital high voltage capacitor ignition that receives its power supply from the battery. Therefore, it works only with an intact battery. When the battery is discharged below the threshold level, the voltage can, due to the starting process, drop below the minimum supply voltage required by the ignition. ! SAFE CAUTION ! AND FAULTLESS OPERATION OF THE DIGITAL IGNITION REQUIRES SPARK PLUG CONNECTORS AND SPARK PLUGS WITH INTEGRATED RESISTANCE TYPE SUPPRESSORS. 7-40D CDI unit Check the cables and plug and socket connections of the CDI unit 1. The CDI unit function can only be checked on an ignition test bench. ! CAUTION NEVER USE A COMMERCIAL MEASURING DEVICE COMMERCIAL MEASURING DEVICES CAN DESTROY COMPONENTS. 1 ! TO CHECK THE CDI UNIT. HIGHLY SENSITIVE ELECTRONIC Check ignition coil – Disconnect all cables and remove the spark plug connector. – Use an ohmmeter to measure the following values. NOTE: The indicated setpoint values correspond to a temperature of 20° C. Replace the ignition coil if the measured values deviate significantly from the setpoint values. MEASUREMENT COLOURS RESISTANCE primary coil blue/white – ground 0,425 – 0,575 Ω secondary coil blue/white – ignition wire 10,80 – 16,20 kΩ Spark plug connector Art.-Nr. 3.206.006 -E – Check the spark plug connector for cracks and fissures. – Measure spark plug connector resistance. Setpoint value: 3.0 – 7.5 kΩ Checking the side stand relay Preparation: – Remove the seat, the right side cover. Swing the headlight mask forward. – Disconnect the power supply from the CDI (orange cable). – To check the current status of the relay connect the orange cable coming from the cable tree either to the positive line of a voltmeter or to a test lamp. – The negative line of the voltmeter or test lamp is connected to ground. – Switch on the ignition lock and the emergency OFF switch. Repair manual KTM LC4 Perform the following tests in the order indicated below: – The relay must connect in either of the following three cases: ● Put a gear in but do not pull the clutch. Slowly swing up the side stand. When the side stand is approximately halfway up, the side stand relay should respond. If this is not the case, please check the relay, the side stand switch 2 as well as the corresponding parts of the cable tree. ● With the side stand down and a gear put in, slowly pull the clutch lever. The side stand relay should respond when the lever is pulled approximately half of the overall distance. If this is not the case, please check the diode in the connector with the yellow and the pink cable and the neutral switch. ● With the side stand down and the clutch not pulled, switch the transmission to neutral. The relay should connect when the transmission is switched to neutral and be tripped when a gear is put in. If this is not the case, please check the diode in the connector with the yellow and the green/black cable and the neutral switch. 2 NOTE: Responding of the relay is accompanied by a faint clicking sound and the CDI’s power supply is switched on. The voltmeter or the test lamp indicates a battery voltage. After testing, reconnect the CDI unit’s power supply (orange cable). 7-41D Checking the side stand switch – Disconnect the 2 connectors connecting the side stand switch 2 with the cable tree (below the tank). – Connect an ohmmeter to the side stand cable. – Slowly swing up the side stand. – The switch must be open while the side stand is down. – The side stand switch must connect when the side stand is approximately halfway up. – If this is not the case, replace the side stand switch. ! CAUTION NEVER SHORT-CIRCUIT THE SIDE STAND SWITCH SO AS TO BE THIS WOULD DEACTIVATE THE IGNITION CUT-OFF WITH THE ! ABLE TO DRIVE ON. SIDE STAND DOWN, AND YOUR MOTORCYCLE WOULD NO LONGER COMPLY WITH THE APPLICABLE SAFETY STANDARDS. NOTE: If the side stand is removed, for example when subsequently installing a center stand, the two connectors of the cable tree that lead to the side stand switch must also be connected. Trouble shooting in the ignition system Before checking the ignition system check ● if the ignition lock is in position ● if the emergency off switch is in the position ● if the neutral control lamp is on ● if the motorcycle can be started with the clutch pulled ● if the battery is charged ● the main fuse and the fuse under the headlight mask Check if an ignition spark is produced when the starter is operated. Proceed as follows: – Pull the spark plug connector. – Disconnect the spark plug connector from the ignition cable. – Hold the free end of the ignition cable approximately 5 mm from ground. – A strong spark should be visible when the electric starter is now operated. If the battery is discharged below the threshold level required for electric starting, please use the kickstarter. – If a spark is visible, replace the spark plug connector. – Twist out the spark plug and insert it into the spark plug connector. – Connect the spark plug to ground. A strong spark should be visible at the electrode when the electric starter is now operated. If this is not the case, the spark plug connector or the spark plug is defect. – If no spark is produced during the first test, perform the following checks: ● Does the ignition’s power supply line (orange) carry battery voltage? ● If this is not the case, check the ignition lock, the emergency off switch and, if applicable, the side stand relay as well as the corresponding parts of the cable tree. – If the ignition is sufficiently supplied with power and no spark is produced, check: ● ground connection of CDI unit and ignition coil ● the cable between CDI unit and ignition coil ● pulse generator ● stator ● ignition coil 7-42D DYNAMIC GENERATOR VALUES 400/640 LC4-E / 625 SXC (KOKUSAN 4K-2) Measuring conditions: – remove seat (also side trim and left side cover for Racing model) – all connectors and the ground connection in a non-corroding condition, connectors tightly connected – battery in a startable condition, not fully loaded (start several times for fully loaded battery) Regulator rectifier output – measure the voltage with the measuring leads of the peak voltage adapter directly on the poles of the vehicle battery: – unstressed and stressed for the entire speed range Multimeter display: 14 volts +/- 1 volt NOTE: The black measuring lead on the peak voltage adapter should be applied to the ground (negative terminal). Check the charge current – remove main fuse, apply the multimeter measuring leads (without the peak voltage adapter) to both connectors on the fuse carrier 1 and measure the current (set the multimeter DCA to 10 amperes): 1 – Unstressed (no electric consumer switched on), engine running at idle speed (1400 +/-50 rpm) Art.-Nr. 3.206.006 -E Multimeter display: 6 amperes +/- 0.1 ampere – Stressed (light switched on, horn and brake actuated), engine running at idle speed Multimeter display: 0 amperes +/- 0.1 ampere – Stressed (light switched on, horn and brake actuated), engine running at increasing speed (up to 8000 rpm) Repair manual KTM LC4 Multimeter display: 2 amperes +/- 0.1 ampere 7-43D 6 5 3 s–g s–g 1 2 7-44D STATIC IGNITION VALUES 400/640 LC4-E / 625 SXC (KOKUSAN 4K-2) Measuring conditions: – cold engine – seat, side trim and tank removed – all connectors and the ground connection in a non-corroding condition, connectors tightly connected – battery loaded, ignition switch to position 1 (without light) – the gap between the rotor and pulse generator must be set to 0.75 mm – compression release lever pulled – kick the kick starter forcefully at least 5 times for each measurement NOTE: Before performing a test with the peak voltage adapter, make sure that the orange cable (battery voltage) is applied to the CDI unit and the black and white/black cables are applied to the ground. Check the pulse generator for an output signal – two-pin connector 1 with green and white cable colors (also see circuit diagram on opposite page): 1 4 – Apply the red measuring lead of the peak voltage adapter to the green cable and the black measuring lead to the white cable, disconnect connector 1 to disconnect the CDI unit 2. Multimeter display: 7 volts +/- 1 volt – Same measurement with CDI unit connected 3 Multimeter display: 4 volts +/- 1 volt Art.-Nr. 3.206.006 -E Check the generator phase for detection of the direction of rotation three-pin connector 3 with red/black and black/yellow cables (also see circuit diagram on opposite page): – Apply the red measuring lead of the peak voltage adapter to the red/black cable and the black measuring lead to the black/yellow cable, disconnect connectors 3 and 4 Multimeter display: 17 volts +/- 1 volt – Same measurement with connectors 3 and 4 connected Multimeter display: 12.5 volts +/- 0.5 volt Check the primary voltage output for ignition coil control for output voltage – one-pin connector 5 with blue/white cable (also see circuit diagram on opposite page): – Apply the red measuring lead of the peak voltage adapter to the ground and the black measuring lead S to the blue/white cable, CDI unit 2 and ignition coil 6 connected Repair manual KTM LC4 5 S Multimeter display: 220 volts +/- 10 volts 7-45D 7 8 9 3 s–g s–g 7-46D STATIC GENERATOR VALUES 400/640 LC4-E / 625 SXC (KOKUSAN 4K-2) Measuring conditions: – cold engine – seat, side trim and tank removed – all connectors and the ground connection in a non-corroding condition, connectors tightly connected – battery loaded, ignition switch to position 1 (without light) – compression release lever pulled – kick the kick starter forcefully at least 5 times for each measurement Check the generator output for voltage between the following cable colors – three-pin connector 3 (also see circuit diagram on opposite page), connectors 3 and 4 disconnected; this disconnects the regulator rectifier 7 and the CDI unit: 4 3 – between black/yellow and red/black – between black/yellow and yellow – between red/black and yellow Multimeter display: 17 volts +/- 1 volt NOTE: The measuring leads of the peak voltage adapter can be randomly applied. Art.-Nr. 3.206.006 -E Check generator output for voltage to ground – three-pin connector 3 (also see circuit diagram on opposite page), connectors 3 and 4 connected; this connects the regulatorl rectifier 7 and the CDI unit: – between black/yellow and ground – between yellow and ground – between red/black and ground Multimeter display: 12.5 volts +/- 0.5 volt NOTE: The black measuring lead of the peak voltage adapter must be applied to the ground. Check regulator rectifier output voltage 8 - two-pin connector 9 with cable colors red and black/white disconnected, connectors 3 and 4 connected (also see circuit diagram on opposite page): – between red and black/white (ground) 7 Repair manual KTM LC4 9 Multimeter display: 13 volts +/- 0.5 volt 7-47D 5 4 2 1 3 7-48D STATIC IGNITION VALUES 400/620/625 SC / 660 SMC (KOKUSAN 4K-3, 3C) Measuring conditions: – cold engine – seat, right side trim and tank removed – all connectors and the ground connection in a non-corroding condition, connectors tightly connected – light switch turned off – the gap between the rotor and pulse generator must be set to 0.75 mm – compression release lever pulled – kick the kick starter forcefully at least 5 times for each measurement Check the pulse generator for an output signal – two one-pin connectors 1 with green and red cable colors (also see circuit diagram on opposite page): 1 1 – Apply the red measuring lead of the peak voltage adapter to the green cable and the black measuring lead to the red cable, disconnect both connectors 1 to disconnect the CDI unit 2 Multimeter display: 4.5 volts +/- 0.5 volt – Same measurement with CDI unit connected 3 Multimeter display: 3 volts +/- 0.5 volt NOTE: On 625 SC-models one two-pin connector is used instead of the two one-pin connectors, the colors of the cable are the same. Art.-Nr. 3.206.006 -E Check the generator charging coil for ignition capacitor charge for an output signal– two-pin connector 3 with black/red and red/white cable colors (also see circuit diagram on opposite page): – Apply the red measuring lead of the peak voltage adapter to the black/red cable and the black measuring lead to the red/white cable, disconnect connector 3 to disconnect the CDI unit 2 Multimeter display: 30 volts +/- 5 volts – Same measurement with connectors CDI unit connected Multimeter display: 180 volts +/- 10 volts Check the primary voltage output 4 for ignition coil control (also see circuit diagram on opposite page) for output voltage (blue/white cable color): – Apply the red measuring lead R of the peak voltage adapter to ground and the black measuring lead S to the blue/white cable, CDI unit 2 and ignition coil 5 connected Repair manual KTM LC4 4 5 R S Multimeter display: 180 volts +/- 10 volts 7-49D 6 9 10 11 7-50D STATIC GENERATOR VALUES 400/620/625 SC / 660 SMC (KOKUSAN 4K-3, 3C) Measuring conditions: – cold engine – seat, right side trim and tank removed – all connectors and the ground connection in a non-corroding condition, connectors tightly connected – light switch turned off – compression release lever pulled – kick the kick starter forcefully at least 5 times for each measurement Check the generator output 6 (also see circuit diagram on opposite page) for voltage between the following cable colors: – between yellow and brown (ground), connector 7 disconnected Multimeter display: 15 volts +/- 1 volt – between white and brown (ground), connector 8 disconnected 7 8 Multimeter display: 19 volts +/- 1 volt – Repeat both measurements with connector 7 and 8 connected. The measured values should be the same. Art.-Nr. 3.206.006 -E NOTE: The black measuring lead of the peak voltage adapter must be applied to the ground. Check regulator rectifier output voltage 9 (also see circuit diagram on opposite page, cable colors yellow/red), regulator rectifier bk connected, capacitor bl disconnected: – between yellow/red and brown (ground) Multimeter display: 14 volts +/- 1 volt 10 Repair manual KTM LC4 S NOTE: – The black measuring lead S of the peak voltage adapter must be applied to the ground. – The regulator rectifier bk is located on the right behind the side trim. 7-51D Checking the speedometer sensor and the speedometer (Adventure – from the 2002 model) Checking the speedometer: – Disconnect the connector 1 from the speedometer. NOTE: The connector 1 is located under the cockpit covering. 1 – Switch on the ignition. – Briefly connect pins 2 and 3 (cable colors black/brown and black/orange) with a cable several times while you observe the speed reading. If the speedometer is functioning correctly, the speed should be indicated. 2 3 Checking the speedometer sensor: NOTE: The measurement must be made with the ignition switched on and the plug and socket connection connected. 1 – Use a digital multimeter to measure the voltage at the black cable on connector 1 against the ground. – Slowly turn the front wheel. – The measured value should be over 4.5 volts when the wheel is turned or less than 1 volt when the magnet on the front-wheel hub is within the range of the speed sensor. ! SINCE CAUTION ! YOU MUST MEASURE WITH THE CONNECTOR ATTACHED, MAKE SURE TO CAREFULLY PUSH THE MEASURING TIPS ON THE MULTIMETER THROUGH THE SEALING FROM THE CABLE SIDE AND NOT TO DAMAGE ANY PART OF THE CONNECTOR. 8-1D FUEL SYSTEM INDEX Repair manual KTM LC4 Art.-Nr. 3.206.006 -E MIKUNI BST 40 PART-LOAD SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-4 FULL-LOAD SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-5 DISASSEMBLING THE CARBURETOR . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-6 ASSEMBLING THE CARBURETOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-8 CHECKING/ADJUSTING THE THROTTLE SENSOR . . . . . . . . . . . . . . . . . . .8-9 ADJUST IDLING SPEED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-10 ADJUSTING THE THROTTLE CABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-10 CHECK FLOAT LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-10 DELL’ORTO DISASSEMBLING THE CARBURETOR (DELL’ORTO PHM 40 SD) . . . . . . .8-12 ASSEMBLING THE CARBURETOR (DELL’ORTO PHM 40 SD) . . . . . . . . . .8-13 DISASSEMBLING THE CARBURETOR (DELL’ORTO PHM 38 ND) . . . . . . .8-16 ASSEMBLING THE CARBURETOR (DELL’ORTO PHM 38 ND) . . . . . . . . . .8-18 DISASSEMBLING THE CARBURETOR (DELL’ORTO VHSB 38 QS) . . . . . . .8-21 ASSEMBLING THE CARBURETOR (DELL’ORTO VHSB 38 QS) . . . . . . . . .8-22 CHECK FLOAT LEVEL (DELL’ORTO 38 ND / 40 SD) . . . . . . . . . . . . . . . . .8-25 CHECKING AXIAL CLEARANCE OF FLOAT (DELL’ORTO 38 ND / 40 SD) . .8-25 ADJUST HOT START DEVICE (DELL’ORTO 40 SD) . . . . . . . . . . . . . . . . . .8-25 ADJUSTING THE THROTTLE CABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-26 ADJUSTING THE CHOKE CABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-26 KEIHIN FCR 41 DISASSEMBLING THE CARBURETOR . . . . . . . . . . . . . . . . . . . . . . . . . . .8-28 CHECKING THE CHOKE SLIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-31 CHECKING THE ACCELERATOR PUMP . . . . . . . . . . . . . . . . . . . . . . . . . .8-31 CHECKING THE JET NEEDLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-31 CHECKING THE FLOAT NEEDLE VALVE . . . . . . . . . . . . . . . . . . . . . . . . . .8-31 CHECKING THE THROTTLE VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-31 ASSEMBLING THE CARBURETOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-32 ADJUSTING THE POSITION OF THE THROTTLE VALVE SENSOR . . . . . . .8-35 CHECKING THE THROTTLE VALVE SENSOR . . . . . . . . . . . . . . . . . . . . . .8-36 DISMOUNTING AND INSTALLING THE THROTTLE VALVE SENSOR . . . . .8-36 ADJUST IDLING SPEED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-37 CHECKING/ADJUSTING THE FLOAT HEIGHT . . . . . . . . . . . . . . . . . . . . .8-38 8 8-2D INDEX Repair manual KTM LC4 Art.-Nr. 3.206.006 -E KEIHIN FCR-MX 41 DISASSEMBLING THE CARBURETOR . . . . . . . . . . . . . . . . . . . . . . . . . . .8-40 CHECKING THE CHOKE SLIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-43 CHECKING THE ACCELERATOR PUMP . . . . . . . . . . . . . . . . . . . . . . . . . .8-43 CHECKING THE JET NEEDLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-43 CHECKING THE FLOAT NEEDLE VALVE . . . . . . . . . . . . . . . . . . . . . . . . . .8-43 CHECKING THE THROTTLE VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-43 ASSEMBLING THE CARBURETOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-44 ADJUSTING THE POSITION OF THE THROTTLE VALVE SENSOR . . . . . . .8-47 CHECKING THE THROTTLE VALVE SENSOR . . . . . . . . . . . . . . . . . . . . . .8-48 DISMOUNTING AND INSTALLING THE THROTTLE VALVE SENSOR . . . . .8-48 ADJUST IDLING SPEED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-49 CHECKING/ADJUSTING THE FLOAT HEIGHT . . . . . . . . . . . . . . . . . . . . .8-49 Repair manual KTM LC4 Art.-Nr. 3.206.006 -E 8-3D CARBURETOR - MIKUNI BST 40 8-4D AIR FUEL AIR MIXTURE FUEL Part-load system (Mikuni BST 40) The part-load system supplies the engine with fuel while the throttle slide is closed or only slightly opened. From the float chamber the fuel enters the mixture pipe through the idling jet. There the fuel mixes with the air that flows in through the idling air jet. Then the fuel air mixture reaches the idle adjusting screw and the bypass bores through the mixture pipe. A certain amount of the fuel air mixture is sucked into the intake pipe through the bypass bores. The remaining fuel air mixture is adjusted by the idle adjusting screw and enters the intake pipe through the idling bore. Art.-Nr. 3.206.006 -E 8-5D AIR FUEL AIR MIXTURE FUEL Repair manual KTM LC4 Full-load system (Mikuni BST 40) When the throttle valve is opened the engine speed increases and the negative pressure in the venturi pipe grows. The same negative pressure is transferred to the upper side of the slide membrane and pulls the throttle slide upwards. At the same time the fuel flows from the float chamber through the main jet into the needle jet. There it mixes with the air flowing in through the main air jet. The result is a fuel air mixture. Negative pressure causes this fuel air mixture to flow through the space between the needle jet and the jet needle into the venturi pipe. There it meets the main air flow sucked in by the engine. The precise amount of the mixture released is adjusted in the needle jet. The space through which the mixture passes changes depending on the position of the throttle slide. Throttle slide in top position: large space Throttle slide in bottom position: small space 8-6D Disassembling the carburetor (Mikuni BST-40) NOTE: Before commencing to disassemble the carburetor make sure that your workplace is clean and large enough to properly arrange all carburetor components before you. ! CAUTION ! TO PREVENT DAMAGING OF THE SLIDE MEMBRANE DO NOT APPLY COMPRESSED AIR TO CLEAN THE CARBURETOR BEFORE REMOVING THE MEMBRANE. – Remove the two screws 1 and take off the membrane cover. – Remove the throttle stop. 1 – Take the throttle slide out of the carburetor together with the spring. – Pull the jet needle 2 out of the throttle slide. 2 – Remove the 2 screws 3 and take off the float chamber together with the gasket. 3 8-7D – Take the entire float unit 1 out of the carburetor. 1 4 2 – Then remove the main jet 2 together with the distance bushing. – Remove the idling jet 3. – Twist the mixture adjusting screw 4 clockwise all the way in. Count and write down the number of twists. Twist out the mixture adjusting screw and remove it together with the spring, the O-ring and the washer. Repair manual KTM LC4 Art.-Nr. 3.206.006 -E 3 5 – Use a screwdriver to push the needle jet 5 upwards out of the carburetor. – Clean all jets and blow them through with compressed air. – Clean the carburetor housing and use compressed air to blow through all ducts within the carburetor. 8-8D Assembling the carburetor (Mikuni BST 40) – Put the needle jet into the carburetor, making sure that the flat portion A is located next to the jet needle. A 3 – Put the distance bushing 1 onto the needle jet and mount the main jet 2. – Mount the spring, the washer and a new O-ring on the mixture adjusting screw 3 and twist the mixture adjusting screw all the way in. – Then twist the mixture adjusting screw back out, applying the same number of twists you have written down when disassembling the device. 2 1 – Mount the idling jet 4. 4 – Insert the float unit 5 into the carburetor. 5 6 – Mount the float chamber together with a new gasket and tighten both screws 6. 8-9D – Mount the throttle slide, making sure that the membrane of the throttle slide rests properly against the round wall of the carburetor housing. – Insert the spring into the throttle slide. – Put the throttle stop 1 into the membrane cover. NOTE: The throttle stop shown in the picture is fitted in a restricted version. 1 2 Art.-Nr. 3.206.006 -E 2 – Mount the membrane cover and fasten it with the two screws 2. Checking the throttle sensor (from model 2003 on) NOTE: the adjustment must be made in a mounted condition with the cable connected and the ignition switched on. – Use a digital multimeter to measure the voltage between the black and yellow cables at the connector 3 (CDI). ! CAUTION ! Repair manual KTM LC4 SINCE YOU MUST MEASURE WITH THE CONNECTOR ATTACHED, MAKE SURE TO CAREFULLY PUSH THE MEASURING TIPS ON THE MULTIMETER THROUGH THE SEALING FROM THE CABLE SIDE AND NOT TO DAMAGE ANY PART OF THE CONNECTOR. 3 – Reading with closed throttle (neutral position): 0.88 +/- 0,075 volts – Slowly open the throttle valve with the throttle grip, the measured voltage should increase uniformly up to the full load reading. – Reading with fully opened throttle grip (full throttle position): 3,88 +/- 0,1 volts. Adjusting the throttle sensor – Loosen the screw on the throttle sensor 4 and turn the throttle sensor until you reach the reading for the neutral position. – Tighten the screw on the throttle sensor. 4 8-10D Adjust idling speed NOTE: Warm up the engine before adjusting the idle speed. Use the adjusting screw 1 to adjust the basic position of the throttle valve and, thus, the idle speed. Turning in clockwise direction will increase the idling speed, turning in counterclockwise direction will reduce the idling speed. Normal idling speed 1400 - 1500 rpm. 1 Adjusting the throttle cable 3-5 mm 2 3 4 A play of 3-5 mm must at any time be left in the throttle cables. To check the play of the throttle cables, first push back the protective cap 2 on the throttle twist grip. Now it should be possible to lift the outer sleeve of one of the two cables 3-5 mm off the adjusting screw 4 before resistance is felt. The play of the throttle cables can be adjusted, if necessary, using the two adjusting screws. For this purpose, undo counter nut 3 and turn the adjusting screw until the desired play is achieved. Then tighten the counter nut and replace the protective cap. After adjusting the throttle cables turn the handlebar all the way to the left and to the right while the engine is still running. The idle speed should not change. Check float level Take off the float chamber, press down the float frame and hold carburator as shown in the picture. The float 5 mooves downwards. 5 Turn carburator slowly until the float moves towards the carburator. In this position the edge of the float 6 must be parallel to the sealing surface of the carburator 7. ! CAUTION ! IF YOU HOLD ON TURNING THE CARBURATOR, THE FLOAT WILL PRESS AGAINST THE SPRING OF THE NEEDLE VALVE AND A CORRECT CHECK IS NOT POSSIBLE. IN THAT CASE THE CARBURATOR IS TO BE TURNED BACK AND THE CHECK MUST BE DONE TWICE. If the two edges are not parallel, correction can be done by bending the lever of the needle valve. At the end a check is necessary again. 6 7 Repair manual KTM LC4 Art.-Nr. 3.206.006 -E 8-11D CARBURETOR – DELL’ORTO PHM 40 SD 8-12D Disassembling the carburetor (Dell’Orto PHM 40 SD) NOTE: Before commencing to disassemble the carburetor make sure that your workplace is clean and large enough to properly arrange all carburetor components before you. – Remove the two screws and pull the carburetor cover out of the carburetor together with the throttle slide. – Wrap the throttle slide in a clean piece of cloth and put it onto the air filter box. – Undo screw bk and take the starting piston out of the carburetor. 10 – Remove the plug 1 together with the seal ring and take off the float chamber. 1 2 – Remove the main jet 2, the main jet holder 3 and the baffle 4. – Twist out the starting jet 5. 4 3 5 6 – Remove the idling jet 6 together with the idle mixture pipe below. – Twist out the needle jet 7. 7 – Pull out the pin 8 and remove the float. – Remove the entire needle valve 9 together with the gasket behind. 8 9 8-13D – Twist the mixture adjusting screw 1 clockwise all the way in, counting and writing down the number of twists. Twist out the mixture regulating screw and remove it together with the spring, the washer and the O-ring. 3 – Twist the adjusting screw 2 clockwise all the way in, counting and writing down the number of twists. Twist out the adjusting screw and remove it together with the spring, the O-ring and the washer. 1 2 – Remove screw 3, and take off the hose connection together with the fuel filter 4. 3 – Clean all jets and other components and blow them through with compressed air. – Clean the carburetor housing and use compressed air to blow through all ducts within the carburetor. – Check all gaskets for damage and exchange them, if necessary. 4 Assembling the carburetor (Dell’Orto PHM 40 SD) Art.-Nr. 3.206.006 -E – Put the spring, the washer and the O-ring onto the mixture adjusting screw 1 and twist the mixture adjusting screw all the way in. – Twist out the mixture adjusting screw, applying the same number of twists previously written down during the disassembly of the device. – Put the spring, the washer and the O-ring onto the adjusting screw 2 and twist the adjusting screw all the way in. – Twist out the adjusting screw, applying the same number of twists previously written down during the disassembly of the device. – Insert the fuel filter into the carburetor. Properly position the hose connection and mount screw 3 together with the seal ring. Repair manual KTM LC4 3 1 2 – Insert the seal ring into the carburetor bore and mount the needle valve 5. 5 8-14D – Position the float and mount the pin 1. When mounting the float make sure that the needle valve properly engages with the float. Check by moving the float upwards: the needle valve must move with the float. 1 – Mount the idling mixture pipe and the idling jet 2. – Mount the needle jet 3. 2 3 6 – Position the baffle 4 and fasten it with the main jet holder 5. – Mount and tighten the main jet 6. – Mount and tighten the starting jet 7. 4 5 7 Check the O-ring 8 in the float chamber for proper fit. 8 9 – Position the float chamber and fasten it with the plug 9. Do not forget the seal ring. Repair manual KTM LC4 Art.-Nr. 3.206.006 -E 8-15D CARBURETOR – DELL’ORTO PHM 38 ND 8-16D Disassembling the carburetor (Dell’Orto PHM 38 ND) NOTE: Before commencing to disassemble the carburetor make sure that your workplace is clean and large enough to properly arrange all carburetor components before you. – Remove the two screws and pull the carburetor cover out of the carburetor together with the throttle slide. – Wrap the throttle slide in a clean piece of cloth and put it onto the air filter box. – Undo screw and take the starting piston out of the carburetor. – Remove the plug 1 together with the seal ring and take off the float chamber. 1 – Remove the main jet 2, the main jet holder 3 and the baffle 4. – Twist out the starting jet 6. – Twist out the return valve 5. 2 3 4 5 6 – Remove the idling jet 8 together with the idle mixture pipe below. – Twist out the needle jet 7. 8 7 – Pull out the pin 9 and remove the float. – Remove the entire needle valve bk together with the gasket behind. 9 10 8-17D – Twist the mixture adjusting screw 1 clockwise all the way in, counting and writing down the number of twists. Twist out the mixture regulating screw and remove it together with the spring, the washer and the O-ring. – Twist the adjusting screw 2 clockwise all the way in, counting and writing down the number of twists. Twist out the adjusting screw and remove it together with the spring, the O-ring and the washer. 1 2 – Remove screw 3, and take off the hose connection together with the fuel filter. 3 Art.-Nr. 3.206.006 -E – Twist out the jet holder 4 together with the accelerating jet 5. 4 5 – Remove the 3 screws 6 and take off the entire pump housing 7 together with the gasket. Repair manual KTM LC4 7 6 8 ! CAUTION ! – DO NOT DAMAGE THE MEMBRANE WHEN REMOVING THE PUMP HOUSING. REMOVE THE MEMBRANE BEFORE CLEANING THE PUMP HOUSING. – ADJUSTMENT SCREW 8 IS FACTORY CALIBRATED AND MUST NOT BE TURNED. – Clean all jets and other components and blow them through with compressed air. – Clean the carburetor housing and use compressed air to blow through all ducts within the carburetor. – Check all gaskets for damage and exchange them, if necessary. 8-18D Assembling the carburetor (Dell’Orto PHM 38 ND) – Position the pump housing 1 together with the gasket and fasten them with the 3 screws. Make sure that the membrane is properly positioned in the pump housing. 1 2 – Put the seal ring onto the jet holder 3 and mount the jet holder together with the accelerating jet 4. The flat section of the accelerating jet must face backwards. 3 4 – Insert the fuel filter into the carburetor. Position the hose connection and mount screw 5 together with the seal ring. 5 7 – Put the spring, the washer and the O-ring onto the mixture adjusting screw 6 and twist the mixture adjusting screw all the way in. – Twist out the mixture adjusting screw, applying the same number of twists previously written down during the disassembly of the device. – Put the spring, the washer and the O-ring onto the adjusting screw 7 and twist the adjusting screw all the way in. – Twist out the adjusting screw, applying the same number of twists previously written down during the disassembly of the device. 6 – Insert the seal ring into the carburetor bore and mount the needle valve 8. 8 8-19D – Position the float and mount the pin 1. When mounting the float make sure that the needle 2 valve properly engages with the float. Check by moving the float upwards: the needle valve must move with the float. 1 2 – Mount the idling mixture pipe and the idling jet 4. – Mount the needle jet 3. 4 3 – – – – Art.-Nr. 3.206.006 -E 7 6 Position the baffle 5 and fasten it with the main jet holder 6. Mount and tighten the main jet 7. Mount and tighten the starting jet 8. Mount the return valve 9. 5 8 9 Check the O-ring bk in the float chamber for proper fit. Repair manual KTM LC4 10 – Position the float chamber and fasten it with the plug bl. Do not forget the seal ring. 11 8-20D CARBURETOR – DELL’ORTO VHSB 38 QS 8-21D Disassembling the carburetor (Dell’Orto VHSB 38 QS) NOTE: Before commencing to disassemble the carburetor make sure that your workplace is clean and large enough to properly arrange all carburetor components before you. – Open the cap and pull the carburetor cover out of the carburetor together with the throttle slide. – Wrap the throttle slide in a clean piece of cloth and put it onto the air filter box. – Undo the screw and pull the entire cold-starting device out of the carburetor. – Remove the three screws 1 and take off the float chamber together with the gasket. – Take the two floats out of the carburetor. – Take the perforated bushing off the baffle. 1 Art.-Nr. 3.206.006 -E 2 – Remove the main jet 2 and the baffle 3. – Twist out the starting jet 4 and the idling jet 5. 3 5 4 – Pull out pin 6 and remove the float arm 7. Repair manual KTM LC4 7 6 – Remove the entire needle valve 8 together with the seal ring behind. 8 8-22D – Twist out the needle jet 1. 1 – Twist the mixture adjusting screw 2 clockwise all the way in, counting and writing down the number of twists. Twist out the mixture regulating screw and remove it together with the spring, the washer and the O-ring. 3 – Twist the adjusting screw 3 clockwise all the way in, counting and writing down the number of twists. Twist out the adjusting screw and remove it together with the spring. 2 – Remove plug 5 together with the seal ring and take off the fuel filter 4. – Clean all jets and other components and blow them through with compressed air. – Clean the carburetor housing and use compressed air to blow through all ducts within the carburetor. 4 – Check all gaskets for damage and exchange them, if necessary. 5 Assembling the carburetor (VHSB 38 QS) – Put the spring, the washer and the O-ring onto the mixture adjusting screw 2 and twist the mixture adjusting screw all the way in. – Twist out the mixture adjusting screw, applying the same number of twists previously written down during the disassembly of the device. 3 2 – Put the spring, the washer and the O-ring onto the adjusting screw 3 and twist the adjusting screw all the way in. – Twist out the adjusting screw, applying the same number of twists previously written down during the disassembly of the device. – Insert the fuel filter 4 into the plug 5 and mount the plug together with the seal ring. 4 5 8-23D – Mount the needle jet 1. – Insert the seal ring into the carburetor bore and mount the needle valve 2. 1 2 – Position the float arm 3 and mount pin 4. 3 4 – Mount the idling jet 5 and the starting jet 6. – Position the baffle 7 and fasten it with the main jet 8. Art.-Nr. 3.206.006 -E 8 7 6 5 – Put the perforated bushing 9 onto the baffle and mount the gasket. Repair manual KTM LC4 9 – Insert the two floats bk into the float chamber and mount the float chamber. 10 8-24D main jet jet needle jet needle idling jet throttle valve mixture regulating screw idle adjusting screw Idling range – A Operation with closed throttle valve. This range is influenced by the position of the air control screw 1 and the idle adjusting screw 2. Idling adjustment of the carburetor strongly affects the engine’s starting behavior. That is, an engine whose idling speed is adjusted correctly will be easier to start than one whose idling speed has not been adjusted correctly. The throttle stop screw is used to adjust the basic position of the throttle. The mixture control screw is used to control the idle mixture which arrives at the engine via the idle system. Turning it clockwise will reduce the amount of gasoline (lean mixture), turning it counterclockwise will increase the amount of gasoline (rich mixture). TO ADJUST IDLING CORRECTLY, PROCEED AS FOLLOWS: 1 Turn in mixture control screw up to the stop, and turn it back out by 1.5 turns 2 Warm up the engine 3 Use throttle stop screw to adjust normal idling speed (1400-1500 r.p.m.) 4 Turn mixture control screw slowly clockwise until idling speed starts to decrease. Memorize this position, and turn mixture control screw slowly counterclockwise until the idling speed will decrease again. Adjust the point of the highest idling speed between these two positions. (The highly competitive user will make his adjustment 1/4 turn leaner because his engine will heat up more in competitive use). NOTE: If you fail to obtain a satisfying result by following the procedure described above, an incorrectly dimensioned idling nozzle may be the cause. In case: a) the mixture control screw has been screwed in up to the stop without causing any change in rotational speed, a smaller idling jet has to be installed; b) the engine dies when the mixture control screw is still open by 2 turns, a larger idling jet needs to be selected; Naturally, in cases of jet changes, you have to start your adjusting work from the beginning. 5 Now, use the slide stop screw to adjust the desired idling speed 6 In cases of greater changes in outside temperature and extremely different altitudes, the idling speed should be readjusted. Opening up – B Engine behavior when the throttle opens. The idle jet and the shape of the throttle valve influences this range. If, despite good idling-speed and part-throttle setting, the engine sputters when the throttle is fully opened and develops its full power not smoothly but suddenly at high engine speeds, the mixture to the carburetor will be too rich, the fuel level too high or the float needle is leaking. Part-throttle range – C Operation with partly open throttle valve. This range is only influenced by the jet needle (shape and position). The optimum partthrottle setting is controlled by the idling setting in the lower range and by the main jet in the upper range. Full throttle range – D Operation with the throttle fully open (flat out). This range is influenced by the main jet and the jet needle. If the porcelain of the new spark plug is found to have a very bright or white coating after a short distance of riding flat out, a larger main jet is required. If the porcelain is dark brown or black with soot the main jet must be replaced by a smaller one. Basic information on carburetor wear As a result of engine vibrations, throttle valve, jet needle, and needle jet are subjected to increased wear. This wear may cause carburetor malfunction (e.g., overly rich mixture). Therefore, these parts should be replaced after 10000 kilometers (6000 miles). 8-25D Mixture too rich: Too much fuel in proportion to air 2 1 Mixture too lean: Not enough fuel in proportion to air Check float level (Dell’Orto PHM 38ND / 40SD) Stand the carburettor diagonally at about 60° so that the spring in the float needle valve is not pressed together. In this position, the edge of the float should be parallel with the float bowl sealing surface (see illustration). 60° Checking axial play of float (Dell’Orto PHM 38ND / 40SD) Art.-Nr. 3.206.006 -E For proper functioning of the float, there must be an axial play of 0.8 mm (0,03 in). If necessary, slightly abrade and deburr lateral float guide. 0,8 mm Adjust hot start device (Dell’Orto PHM 40SD) If the hot start button was removed when cleaning the carburetor, readjust the hot start device. Install carburetor and adjust idling as discribed above. Then unlock nut 1, press in hot start device 2 and adjust engine rev with adjusting screw 3 to 2000-2500 rpm. Tighten locking nut. Repair manual KTM LC4 3 1 2 8-26D Adjusting the throttle cable There must always be a 3-5 mm (0.1-0.2 in) play in the throttle cable. To check this, move back the protective cover 1 on the throttle grip. You must be able to lift the outer covering of the cable 3-5 mm from the adjusting screw 2, until resistance is felt. To adjust, loosen the counter nut 3 and turn the adjusting screw accordingly. Finally tighten counter nut and slide the protective cover back on. 3-5 mm 3 2 1 Adjusting the choke cable 5 2 mm 4 At the choke cable, there must always exist a play of approx. 2 mm (0.1 in). To check this, push choke lever fully forward and pull protective cover 4 from the adjuster piece 5. Now, it must be possible to lift the outer covering of the cable by approx. 2 mm from the adjuster piece until feeling a resistance. If necessary, loosen counter nut and readjust play by turning the adjuster piece. Tighten counter nut, and slide on protective cover. Adjusting the choke cable The choke cable must have a play of approximately 2 mm at all times. To check the play turn the knob 6 into the initial position. Now it should be possible to lift the exterior case of the choke cable approximately 2 mm from the supporting surface of the choke knob before the upward movement is blocked by resistance. 2 mm 6 7 To adjust, remove the seat and the gastank, push the protective cover upwards, loosen the counter nut and turn the adjustment screw 7 accordingly. Turn the adjustment screw clockwise for more play or anticlockwise for less play. Tighten the counter nut, replace the protective cover and mount the gas-tank and the seat. Repair manual KTM LC4 Art.-Nr. 3.206.006 -E 8-27D CARBURATOR - KEIHIN FCR 41 8-28D Disassembling the carburetor NOTE: Before you start disassembling the carburetor, you should look for a clean work place. It should offer you enough space to lay out all individual components of the carburetor in perfect order. – Dismount the carburetor and remove any coarse dirt. 1 – Remove the wire clip 1 and pull the ventilation hoses out of the carburetor. – Disconnect the hose 2. – Loosen the 2 screws 3 and dismount all ventilation hoses from the carburetor. 3 3 2 – Remove the 2 screws 4 and dismount the slide cover together with its gasket. 4 – Remove the screw 5 and take the jet needle out of the throttle valve. – Remove the screw 6. 5 6 8-29D – Now, pull the cable disc approx. 5 mm outward and turn it until the throttle valve can be lifted out of the carburetor and detach the rollers 1 at the throttle valve. – Take the throttle valve together with the 4 rollers 2 and the valve paddle out of the carburetor. 2 NOTE: When you turn the cable disc, it must not be blocked by the stop bolt (see photo). Otherwise, pull the shaft further outward. 1 – Turn the carburetor around, remove the 3 screws and remove the cover of the accelerator pump. NOTE: When dismounting the cover, watch out for the spring and the sealing rings as they may get lost easily. – Remove the 2 sealing rings, the spring and the diaphragm from the pump housing. Art.-Nr. 3.206.006 -E – Remove the screw and dismount the float chamber. – Unhitch the push rod 3 of the accelerator pump and dismount it. 3 – Take the plastic part 4 off the needle jet. – Loosen the screw 5, pull out the float hinge pin 6 and dismount the float together with the float needle valve. 4 6 Repair manual KTM LC4 5 – Remove the screw 7 and use pliers to carefully extract the seat of the float needle valve from the carburetor. – Turn out the idling jet 8, the starting jet 9 and the needle jet together with the main jet bk. 11 9 8 10 7 – Turn in the mixture control screw bl down to the stop, count the number of turns and write it down. – Turn out the mixture control screw and dismount it together with the spring, the washer, and the O-ring. NOTE: The spring, the washer, and the O-ring will usually remain in the bore. These parts can be removed with the help of compressed air. 8-30D – Remove the screw 1 and dismount the throttle-valve sensor 2. When unfastening the screw, be sure to watch out for the bushing 3. 4 3 NOTE: To dismount the throttle-valve sensor, always remove the screw 1. After the screw 4 was loosened, the throttle-valve sensor must be adjusted again. 1 2 – Remove the screw and the clip together with the bushing and pull the connection piece 5 out of the carburetor. 5 6 – Remove the 2 screws and take the intake trumpet together with the O-ring 6 off the carburetor. – Unscrew the idle-air jet 7 and the main air jet 8. – Thoroughly clean all jets and other parts and blow compressed air through them. – Clean the carburetor housing and blow compressed air through all ducts in the carburetor. 7 8 – Check all gaskets for damage and, if necessary, replace them. 8-31D Checking the choke slide It must be easy to actuate the choke slide. The piston 1 of the choke slide must not have any pronounced score marks or deposits. 1 Checking the accelerator pump Check the membranes for cracking or brittleness. Check gaskets for damage. Check if the bores 2 are unobstructed. 2 2 Checking the jet needle Art.-Nr. 3.206.006 -E Check the jet needle for bending and wear. Checking the float needle valve Repair manual KTM LC4 Check the sealing surface of the needle valve for notches. There must not be any dirt between valve seat and float needle. Checking the throttle valve 4 3 Check the throttle valve paddles 3 for damage. The rollers 4 at the throttle valve must be easy to turn and must not have any flat spots. 8-32D Assembling the carburetor – Mount the idle-air jet 1 and the main air jet 2. – Place the O-ring 3 in the groove and secure the intake trumpet to the carburetor by means of the 2 screws. 3 2 1 – Insert the fuel connection 4 into the carburetor and secure it with the clip. NOTE: In the mounted state, the connection piece must be easy to turn. 4 – Mount the choke slide 5 and actuate it several times, checking whether it can be moved smoothly. Besides, check whether the choke locks properly. 5 – Thread the spring, the washer and the O-ring onto the mixture control screw 6 and screw the mixture control screw in as far as it will go. – Now, unscrew the mixture control screw the number of turns written down during disassembly. 6 NOTE: Basic setting see technical spezifications. 8 – Mount idling jet 7, starting jet 8 and needle jet together with main jet 9. 7 9 – Insert the needle jet bk into bore and secure it by means of the screw bl. 11 10 8-33D – Position the float, mount the float hinge pin and secure it by means of the screw. – Check the float level. – Stick the plastic component 1 on the needle jet. 1 – Engage the push rod 2 of the accelerator pump at the lever. 2 Art.-Nr. 3.206.006 -E – Mount the float chamber and at first secure it with only 1 screw. When positioning the float chamber, make sure that the push rod 2 of the accelerator pump slides into the bore. 2 Repair manual KTM LC4 5 3 – Place the membrane 3 with the labeling facing upwards and the spring into the pump housing. – Place the O-ring 4 into the groove. Secure the sealing ring 5 with some grease in the cover and fasten the cover by means of 3 screws. 4 6 – Turn the cable disc and push the throttle valve into the carburetor such that the rollers 6 engage the throttle valve (see photo). Push the throttle valve all the way into the carburetor. – Turn the cable disc several times and while doing so check whether the throttle valve moves smoothly. 8-34D – Coat the thread of the screw 1 with Loctite 243 and mount the screw, however, do not tighten it yet. – Push the slide pin 2 inward. At the same time, push the slide lever 3 to the extreme right and tighten the screw 1. 2 1 3 – Now, the distances A on the left and on the right should be identical. Then, turn the cable disc and check if the throttle valve moves smoothly. – Mount the jet needle and secure it with the screw 4. A A 4 – Position the slide cover together with its gasket and fasten it by means of the 2 screws 5. 5 – Secure the ventilation hoses with the 2 screws 6 of the float chamber and connect the hose 7. 6 6 7 – Insert the 2 hose connections into the bores and fasten them with the retaining clip 8. 8 8-35D – Mount the throttle valve sensor such that the flat spot at the carburetor engages the groove of the throttle valve sensor and secure it by means of the screw. Adjusting the position of the throttle valve sensor 1 2 NOTE: Before checking the position of the throttle valve sensor, you have to adjust the idle speed correctly. – Disengage the plug-and-socket connection of the throttle valve sensor. – Connect a multimeter (measuring range Ω x 1k) to the blue (+) and the black (-) cable of the throttle valve sensor and measure the throttle valve resistance. – Now, multiply this value by 0.15. This yields the adjustment value for the throttle valve sensor. Example: throttle valve sensor resistance (bl/s) = 5 kΩ throttle valve sensor resistance (ge/s) = 5 kΩ x 0.15 = 750 Ω ± 50 Ω Art.-Nr. 3.206.006 -E – Connect the multimeter (measuring range Ωx100) to the yellow (+) and the black (-) cable of the throttle valve sensor and measure the throttle valve sensor resistance with the throttle grip closed. According to the above example, this value should be 750 Ω ± 50 Ω. – If the value measured does not correspond to the desired value, loosen the screw 1 and turn the throttle valve sensor 2 until the instrument displays the desired value. – Secure the throttle valve sensor in this position by fastening the screw and check the value once more. – Connect the throttle valve sensor to the wiring harness. bl bl ge ge Repair manual KTM LC4 s s 8-36D Checking the throttle valve sensor NOTE: The following measurement must be taken at a component temperature of approx. 20°C. – Open the plug-and-socket connection of the throttle valve sensor. – Connect a multimeter (measuring range Ω x 1k) to the blue (+) and the black (-) cable of the throttle valve sensor. throttle valve sensor resistance: 4 - 6 kΩ bl bl – Now, connect the multimeter to the yellow (+) and the black (-) cable of the throttle valve sensor. – As you open the throttle grip slowly, the resistance must change evenly. ge throttle valve sensor resistance: 0-5 kΩ ±1 kΩ (while opening the throttle grip) ge s bl = blue ge = yellow s = black s Dismounting and installing the throttle valve sensor – Disconnect the plug-and-socket connection of the throttle valve sensor and remove the bolt 1. – Take the throttle valve sensor off the carburetor. 1 – When mounting the throttle valve sensor, make sure that the flat spot at the throttle valve pin 2 engages the groove on the throttle valve sensor. – Mount the bolt, however, do not yet tighten fully and adjust the position of the throttle valve sensor. Secure the bolt with Loctite 243. 2 8-37D Adjust idling Idling adjustment of the carburetor strongly affects the engine’s starting behavior. That is, an engine whose idling speed is adjusted correctly will be easier to start than one whose idling speed has not been adjusted correctly. 1 2 2 The idle speed is controlled by means of the adjusting wheel 1 and the mixture control screw 2. The adjusting wheel is used to adjust the basic setting of the slide. The mixture control screw is used to control the idle mixture which arrives at the engine by way of the idle system. Clockwise turning reduces the fuel quantity (lean mixture), counterclockwise turning increases the fuel quantity (rich mixture). TO ADJUST IDLING CORRECTLY, PROCEED AS FOLLOWS: 1 Turn in mixture control screw 2 up to the stop, and turn it back out to the basic position (see technical data engine) 2 Warm up the engine 3 Use the adjusting wheel 1 to set the normal idle speed (1400 - 1500 rpm). 4 Turn mixture control screw 2 slowly clockwise until idling speed starts to decrease. Memorize this position, and turn mixture control screw slowly counterclockwise until the idling speed will decrease again. Adjust the point of the highest idling speed between these two positions. If, in the course of this procedure, the speed undergoes a relatively high increase, reduce the idle speed to a normal level and repeat the procedure specified in 4. Serious competitive racers will choose a setting approx. 1/4 turn (clockwise) leaner than this ideal value because their engine will heat up more when used in competitions. Repair manual KTM LC4 Art.-Nr. 3.206.006 -E NOTE: If you fail to obtain a satisfying result by following the procedure described above, an incorrectly dimensioned idling nozzle may be the cause. a) If the mixture control screw has been screwed in up to the stop without causing any change in rotational speed, a smaller idling jet has to be installed; b) If the engine dies when the mixture control screw is still open by 2 turns, a larger idling jet needs to be selected; Naturally, in cases of jet changes, you have to start your adjusting work from the beginning. 5 Then, use the adjusting wheel to set the desired idle speed. 6 In cases of greater changes in outside temperature and extremely different altitudes, the idling speed should be readjusted. 8-38D Adjusting the mixture control screw The mixture control screw is difficult to reach. For this reasons, we have created an appropriate special tool 590.29.034.000. Introduce the special tool into the bore at the carburetor bottom. Press the tool slightly upward and turn the adjusting wheel 1 until the tool engages the slot of the mixture control screw 2. Now, you can go about adjusting the screw. Marks were provided on the adjusting wheel, making it easier to keep track of the turns. 1 2 Checking the float level (float height) For this purpose, dismount the carburetor and remove the float chamber. Hold the carburetor in a slanted position such that the float will abut the float needle valve but not compress it (see photo). Now, use a sliding caliper to measure the distance H between the casing edge and the float's upper edge. The float height H is to be 9 mm. If the float height does not correspond to the desired value, check the float needle valve and, if necessary, replace it. H If the float needle valve is correct, you can adjust the float height by bending of the float lever 3. 3 Mount the float chamber, install the carburetor, and adjust the idle speed. Repair manual KTM LC4 Art.-Nr. 3.206.006 -E 8-39D CARBURETOR - KEIHIN FCR-MX 41 8-40D Disassembling the carburetor Keihin FCR - MX 41 NOTE: Before you start disassembling the carburetor, you should look for a clean workplace. It should offer you enough space to lay out all individual components of the carburetor in perfect order. – Dismount the carburetor and remove any coarse dirt. – Loosen both bolts 1 and remove all of the vent hoses from the carburetor. 1 1 – Remove both bolts 2 and remove the slide cover and gasket from the carburetor. 2 2 – Remove screw 3 and pull the jet needle out of the throttle slide. – Remove screw 4. 3 4 5 – Pull the throttle slide arm up and take the throttle slide roller 5 and the slide shim out of the carburetor. 8-41D – Turn the carburetor around, remove the 3 screws and remove the cover of the accelerator pump. NOTE: When dismounting the cover, watch out for the spring and the sealing rings as they may get lost easily. – Remove the 2 sealing rings, the spring and the diaphragm from the pump housing. – Remove the screws on the float chamber and remove the housing. Art.-Nr. 3.206.006 -E 2 – Pull out the float hinge pin 1 and remove the float together with the float needle valve. – Remove the main jet 2. 1 7 4 Repair manual KTM LC4 6 – Remove the screw 3 and use pliers to carefully extract the seat of the float needle valve from the carburetor. – Screw out the idling jet 4, the starting jet 5 and the needle jet 6. – Turn in the mixture control screw 7 down to the stop, count the number of turns and write it down. – Turn out the mixture control screw and dismount it together with the spring, the washer, and the O-ring. NOTE: The spring, the washer, and the O-ring will usually remain in the bore. These parts can be removed with the help of compressed air. 5 3 8-42D – Remove bolts 1 and the throttle sensor 2. 2 1 NOTE: the throttle sensor should only be dismounted if defective. If the bolts 1 are loosened, the throttle sensor must be adjusted again. 1 – Remove screw 3 and pull the connecting piece out of the carburetor. 3 4 5 6 – Remove the 2 screws and take the intake trumpet together with the O-ring 4 off the carburetor. – Unscrew the idle-air jet 5 and the main air jet 6. – Thoroughly clean all jets and other parts and blow compressed air through them. – Clean the carburetor housing and blow compressed air through all the ducts in the carburetor. – Check all gaskets for damage and, if necessary, replace them. 8-43D Checking the choke slide and hot start knob Choke slide: The choke slide must be easy to actuate . The piston 1 of the choke slide must not have any pronounced score marks or deposits. 1 Hot start knob: The hot start knob must be easily actuated. The piston on the hot start knob may not have any scores or deposits. Checking the accelerator pump Check the membranes for cracking or brittleness. Check gaskets for damage. Check if the bores 2 are unobstructed. 2 2 Checking the jet needle Art.-Nr. 3.206.006 -E Check the jet needle for bending and wear. Checking the float needle valve Repair manual KTM LC4 Check the sealing surface of the needle valve for notches. There must not be any dirt between the valve seat and the float needle. Checking the throttle valve 3 4 The rollers 3 at the throttle valve must be easy to turn and must not have any flat spots. Check the throttle valve paddles 4 for damage. 8-44D Assembling the carburetor Keihin FCR-MX 41 3 1 – Mount the idle-air jet 1 and the main air jet 2. – Place the O-ring 3 in the groove and secure the intake trumpet to the carburetor by means of the 2 screws. 2 – Insert the fuel port in the carburetor and fix with screw 4. NOTE: In the mounted state, the connection piece must be easy to turn. 4 – Mount the choke slide 5, the hot start knob 6 and actuate several times, checking for smooth operation. Also make sure the choke and the hot start knob lock into place. 5 6 – Thread the spring, the washer and the O-ring onto the mixture control screw 7 and screw the mixture control screw in as far as it will go. – Now, unscrew the mixture control screw the number of turns written down during disassembly. 7 8 NOTE: See the Technical Specifications for the basic carburetor setting. 10 – Mount idling jet 8, starting jet 9 and needle jet together with main jet bk. 9 – Insert the needle valve seat bl in the bore and fix with screw bm. 12 11 8-45D – Position the float and the float needle valve and mount the float hinge pin 1. – Check the float level (see page 8-21). 1 – Mount the float chamber and the gasket, position the bracket for the adjustment screw 2 and fix the float chamber with the screws 3. NOTE: When positioning the float chamber, make sure that the push rod 4 of the accelerator pump slides into the bore. 2 3 4 – Place the membrane 5 with the labeling facing upwards and the spring into the pump housing. – Place the O-ring 6 into the groove. Secure the sealing ring 7 with some grease in the cover and fasten the cover by means of 3 screws. Art.-Nr. 3.206.006 -E 5 7 6 Repair manual KTM LC4 – Mount the throttle valve sensor such that the flat spot at the carburetor engages the groove of the throttle valve sensor and secure it by means of the bolt. 8 9 – Pull up the throttle slide arm, push the throttle slide together with roll 8 and the slide shim into the carburetor so that the rolls 9 engage in the throttle slide (see illustration). – Check the throttle slide for smooth operation. 8-46D – Apply Loctite 243 to the screw 1 and tighten. – Mount the jet needle and fix with the screw 2. 2 1 – Position the slide cover with the gasket and fasten with the 2 screws 3. 3 3 – Fix the vent hoses on the float chamber with the 2 bolts 4. 4 4 8-47D Adjusting the position of the throttle valve sensor 2 1 NOTE: Before checking the position of the throttle valve sensor, you have to adjust the idle speed correctly. – Disengage the plug-and-socket connection of the throttle valve sensor. – Connect a multimeter (measuring range Ω x 1k) to the blue (+) and the black (-) cable of the throttle valve sensor and measure the throttle valve resistance. – Now, multiply this value by 0.15. This yields the adjustment value for the throttle valve sensor. 1 Example: Throttle valve sensor resistance (bl/s) = 5kΩ Throttle valve sensor resistance (ge/s) = 5 kΩ x 0.15 = 750 Ω ± 50 Ω – Connect the multimeter (measuring range Ωx100) to the yellow (+) and the black (-) cable of the throttle valve sensor and measure the throttle valve sensor resistance with the throttle grip closed. According to the above example, this value should be 750Ω ± 50Ω. – If the value measured does not correspond to the desired value, loosen the 2 bolts 1 and turn the throttle valve sensor 2 until the instrument displays the desired value. – Secure the throttle valve sensor in this position by fastening the bolts and check the value once more. – Connect the throttle valve sensor to the wiring harness. Repair manual KTM LC4 Art.-Nr. 3.206.006 -E bl bl ge ge s bl = blue ge = yellow s = black s 8-48D Checking the throttle valve sensor NOTE: The following measurement must be taken at a component temperature of approx. 20°C. – Open the plug-and-socket connection of the throttle valve sensor. – Connect a multimeter (measuring range Ω x 1k) to the blue (+) and the black (-) cable of the throttle valve sensor. Resistance of throttle valve sensor: 4 - 6 kΩ bl bl – Now, connect the multimeter to the yellow (+) and the black (-) cable of the throttle valve sensor. – As you open the throttle grip slowly, the resistance must change evenly. ge Resistance of throttle valve sensor: 0-5 kΩ ±1 kΩ (while opening the throttle grip) ge s s bl = blue ge = yellow s = black Dismounting and installing the throttle valve sensor 1 – Disconnect the plug-and-socket connection of the throttle valve sensor and remove the bolts 1. – Take the throttle valve sensor off the carburetor. 1 – When mounting the throttle valve sensor, make sure that the flat spot at the throttle valve pin engages the groove on the throttle valve sensor. – Mount the 2 bolts, however, do not yet tighten them fully and adjust the position of the throttle valve sensor. Secure the 2 bolts with Loctite 243. 8-49D CARBURETOR – Adjust idling (Keihin FCR-MX 41) Idling adjustment of the carburetor strongly affects the engine’s starting behavior. That is, an engine whose idling speed is adjusted correctly will be easier to start than one whose idling speed has not been adjusted correctly. The idle speed is controlled by means of the adjusting wheel 1 and the mixture control screw 2. The adjusting wheel is used to adjust the basic setting of the slide. The mixture control screw is used to control the idle mixture which arrives at the engine by way of the idle system. Clockwise turning reduces the fuel quantity (lean mixture), counterclockwise turning increases the fuel quantity (rich mixture). TO ADJUST IDLING CORRECTLY, PROCEED AS FOLLOWS: 1 Turn in mixture control screw 2 up to the stop, and turn it back out to the basic position (see technical date-engine) 2 Warm up the engine 3 Use the adjusting wheel 1 to set the normal idle speed (1400 1500 rpm). 4 Turn mixture control screw 2 slowly clockwise until idling speed starts to decrease. Memorize this position, and turn mixture control screw slowly counterclockwise until the idling speed decreases again. Adjust the point of the highest idling speed between these two positions. If, in the course of this procedure, the speed undergoes a relatively high increase, reduce the idle speed to a normal level and repeat the procedure specified in 4. Serious competitive racers will choose a setting approx. 1/4 turn (clockwise) leaner than this ideal value because their engine will heat up more when used in competitions. NOTE: If you fail to obtain a satisfying result by following the procedure described above, an incorrectly dimensioned idling nozzle may be the cause. If: a) the mixture control screw has been screwed in up to the stop without causing any change in rotational speed, a smaller idling jet has to be installed; b) the engine dies when the mixture control screw is still open by 2 turns, a larger idling jet needs to be selected. Naturally, in cases of jet changes, you have to start your adjusting work from the beginning. 5 Then, use the adjusting wheel to set the desired idle speed. 6 In cases of greater changes in the outside temperature and extremely different altitudes, the idling speed should be readjusted. 1 Art.-Nr. 3.206.006 -E 2 3 Basic information on carburetor wear As a result of engine vibrations, the throttle valve, jet needle, and needle jet are subjected to increased wear. This wear may cause the carburetor to malfunction (e.g., overly rich mixture). Therefore, these parts should be replaced after 200 hours. Adjusting the mixture control screw Especially on the EXC models, accessing the mixture control screw is difficult. For this reasons, we have created an appropriate special tool. Repair manual KTM LC4 Introduce the special tool on the mixture control screw 2 at the carburetor bottom. Press the tool slightly upward and turn the adjusting wheel 3 until the tool engages the slot of the mixture control screw. Now, you can go about adjusting the screw. Marks were provided on the adjusting wheel, making it easier to keep track of the turns. Checking the float level (float height) 4 For this purpose, dismount the carburetor and remove the float chamber. Hold the carburetor in a slanted position such that the float will abut the float needle valve but not compress it. In this position, the edge of the float should be parallel with the float chamber sealing surface (see illustration). If the float height does not correspond to the desired value, check the float needle valve and, if necessary, replace it. If the float needle valve is o.k., you can adjust the float height by bending the float lever 4. Mount the float chamber, install the carburetor, and adjust the idle speed. 9-1D TROUBLE SHOOTING INDEX Repair manual KTM LC4 Art.-Nr. 3.206.006 -E TROUBLE SHOOTING (SX, SXC, SC, SMC) . . . . . . . . . . . . . . . . . . . .9-2 TROUBLE SHOOTING (LC4 COMPETITION) . . . . . . . . . . . . . . . . . . .9-4 TROUBLE SHOOTING (LC4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-7 9 9-2 TROUBLE SHOOTING – SX, SXC, SC, SMC TROUBLE Art.-Nr. 3.206.006 -E Engine will not start Repair manual KTM LC4 Engine will not idle Engine does not rev high REMEDY CAUSE Operating error Switch on ignition, switch on emergency OFF switch, open fuel tap, tank fuel, do not use choke i.e. the hotstart device. Pay attention to starting off information (see driving instructions). Fuel supply interrupted Close fuel tap, loosen fuel hose at carburettor, lead into a basin and open fuel tap, – if fuel leaks out, clean carburettor – if no fuel leaks out, check tank ventilation, i.e. clean fuel tap Flooded engine See driving instructions Sooty or wet spark plug Clean or replace spark plug Electrode gap too large Adjust spark plug electrode gap to 0,6 mm Spark plug connector or spark plug faulty Dismount spark plug, connect ignition cable, hold to ground (blank place on engine) and actuate kickstarter, a strong spark must be produced at the spark plug – If no spark is produced, loosen spark plug cap from ignition cable, hold about 5 mm from ground and actuate kickstarter – If a spark now occurs, replace spark plug cap – If no spark is produced, control ignition system If connector oxidates generator to ignition coil from Remove fuel tank, clean connector and treat with contact spray Short circuit cable scored in wiring harness, ignition lock, emergency OFF switch or short circuit button faulty Remove fuel tank, draw off blue/black cable from orange cable of ignition coil and check spark. – If a spark is produced, seek fault in short circuit current The plug connection of the CDIunit, the pulse generator or the ignition coil has oxydized Remove the seat, the right side cover and the fuel tank. Clean the plug connection and treat it with contact spray Water in short emergency OFF switch Remove 2-pole connector located underneath the headlight mask, treat emergency OFF switch with contact spray Water in carburettor or jets blocked Dismount and clean carburettor Carburettor does not fit in properly at intake flange Check if carburettor is fitted in correctly Idling jet blocked Dismount carburettor and clean jets Adjusting screws on carburettor uncorrect adjusted Adjust carburettor Ignition system faulty Check ignition system Carburettor fuel level too high because float needle valve is dirty or worn out Dismount carburettor and check if worn out Loose carburettor jets Tighten jets Electronical ignition timing faulty Check ignition system 9-3D REMEDY TROUBLE CAUSE Engine will not reach full power Fuel supply partically interrupted or carburettor dirty Clean and check fuel system as well as carburettor Float is not tight, or no axial play Replace or abrade the float Air filter very dirty Clean or replace air filter Exhaust leaking or blocked Check if exhaust is damaged, replace glas fibre yarn in exhaust silencer Valve gap to small Adjust valve gap Loss of compression because hand decompressor has no play Check setting of the hand decompression cable Electronical ignition timing faulty Check ignition system Insuffient fuel Clean and check fuel system and carburettor Engine takes air out of control Check intake flange and carburettor if firmly setted Insufficient cooling liquid Refill cooling liquid (see maintenace work), check cooling system for leaks Not enough air stream Drive on briskly Radiators very dirty Clean radiators with water jet Foam formation in cooling system Replace cooling liquid, use anti freeze liquid with brand name Bent cooling hose Shorten or replace cooling hose Thermostat defective Dismount and check thermostat (opening temperature 70° C, 158° F) or replace it Buckling gearing ventilation hose Dislocate i.e. replace non-buckling vetilation hose Engine oil level too high Check engine oil level when the engine is warm; correct if necessary Motor oil too thin (viscosity) Use thicker engine oil; see chapter „Engine oil“ Capacitor faulty Remove right side cover and control connections. Check capacitor and voltage regulator Engine stops or splutters in carburettor Engine gets to hot, High oil consumption All switched blown out on lamps or voltage regulator 9-4D TROUBLE SHOOTING – LC4 COMPETITION TROUBLE Repair manual KTM LC4 Art.-Nr. 3.206.006 -E Engine will not start Engine will not idle REMEDY CAUSE Operating error Switch on ignition, switch on emergency OFF switch, open fuel tap, tank fuel, do not use choke i.e. the hotstart device. Pay attention to starting off information (see driving instructions). The motorcycle has been out of operation for a longer period of time. Therefore the float chamber is filled with old fuel. The easily inflammable components of the new fuels evaporate during longer periods of standstill. When the motorcycle has been out of operation for more than a week, it is therefore recommended to drain the old fuel from the float chamber. The engine will immediately start off when the float chamber is filled with new fuel. Fuel supply interrupted Close fuel tap, loosen fuel hose at carburetor, lead into a basin and open fuel tap, – if fuel leaks out, clean carburetor – if no fuel leaks out, check tank ventilation, i.e. clean fuel tap Flooded engine Fully open the throttle when starting or replace the spark plug, respectively. Sooty or wet spark plug Clean / dry or replace spark plug. Electrode gap too large Adjust spark plug electrode gap to 0,7 mm Spark plug connector or spark plug faulty Dismount spark plug, connect ignition cable, hold to ground (blank place on engine) and actuate kickstarter, a strong spark must be produced at the spark plug – If no spark is created exchange the spark plug. – If the new spark plug doesn’t produce a spark either, disconnect the spark plug connector from the ignition cable, hold it approx. 5 mm from ground and start. – If a spark now occurs, replace spark plug cap – If no spark is produced, control ignition system If connector oxidates generator to ignition coil from Remove fuel tank, clean connector and treat with contact spray Short circuit cable scored in wiring harness, ignition lock, emergency OFF switch faulty Remove fuel tank, draw off blue/black cable from orange cable of ignition coil and check spark. – If a spark is produced, seek fault in short circuit current Water in short emergency OFF switch Remove 2-pole connector located underneath the headlight mask, treat emergency OFF switch with contact spray Water in carburetor or jets blocked Dismount and clean carburetor Carburetor does not fit in properly at intake flange Check if carburetor is fitted in correctly Idling jet blocked Dismount carburetor and clean jets Adjusting screws on carburetor uncorrect adjusted Adjust carburetor Spark plug faulty Exchange the spark plug Ignition system faulty Check ignition system 9-5D REMEDY CAUSE TROUBLE Carburetor fuel level too high because Dismount carburetor and check if worn out Float needle is dirty or worn out Replace float needle Float leaks Replace float The cold starting system is permanently activated due to a lack of play in the choke cable. Adjust choke cable. Carburetor jets have loosened. Retighten jets. Defective electronic ignition timing device. Check ignition system Fuel supply partically interrupted or carburetor dirty Clean and check fuel system as well as carburetor Float is not tight Replace the float Air filter very dirty Clean or replace air filter Valve gap to small Adjust valve gap Loss of compression because hand decompressor has no play Check setting of the hand decompression cable Electronical ignition timing faulty Check ignition system Insufficient cooling liquid Refill cooling liquid (see maintenace work), check cooling system for leaks Radiators very dirty Clean radiators with water jet Foam formation in cooling system Replace cooling liquid, use anti freeze liquid with brand name Bent cooling hose Shorten or replace cooling hose Thermostat defective Dismount and check thermostat (opening temperature 70°C, 158°F) or replace it Buckling gearing ventilation hose Dislocate i.e. replace non-buckling ventilation hose Engine oil level too high Check engine oil level when the engine is warm; correct if necessary Motor oil too thin (viscosity) Use thicker engine oil; see chapter „Engine oil“ All lamps that were on have burned out. Defective voltage regulator. Remove seat, check connections, Check the voltage regulator Headlight light fail. parking Blown fuse. Replace fuse (below the headlight mask). Flasher lights, brake light, fan and horn fail. Blown fuse Replace fuse (below the headlight mask). Engine does not rev high Engine will not reach full power Engine gets to hot, cooling liquid tmperature warning lamp lights up High oil consumption and 9-6D TROUBLE The neutral indicator lamp doesn’t light up when the motorcycle is put into neutral. Repair manual KTM LC4 Art.-Nr. 3.206.006 -E Discharged battery. REMEDY CAUSE Defective indicator lamp. Replace indicator lamp. Defective idle switch. Connect the cable to ground. The neutral switch must be replaced if the indicator lamp lights up. Loose connections, defective cable. Check connections and cable. The ignition (power consumer) has been left on. Recharge the battery according to the relevant instructions. The generator doesn’t recharge the battery. Remove the seat and check the voltage regulator connections. Check the voltage regulator and the generator. 9-7D TROUBLE SHOOTING LC4 TROUBLE CAUSE REMEDY Operating errror Turn on the ignition, switch the gear to neutral and switch the emergency OFF switch on. Discharged battery. Recharge the battery and investigate the causes for discharging. Defect ignition lock or emergency OFF switch Check ignition lock and emergency OFF switch. The engine doesn't crank. The neutral indicator lamp doesn't light up. Blown fuse safe-starting system. Replace fuse (below the headlight mask). Blown main fuse. Remove seat and replace the main fuse. The engine cranks only with pulled clutch lever Defect safe-starting system. Check the components of the safe-starting system. Engine cranks with gear engaged. Defect safe-starting system. Check the components of the safe-starting system. Engine cranks but doesn’t start. Operating error Open fuel tap, tank fuel, you did not use choke i.e. the warmstart device. Pay attention to starting off information (see driving instructions). The motorcycle has been out of operation for a longer period of time. Therefore old fuel has accumulated in the float chamber The easily inflammable components of the new fuels evaporate during longer periods of standstill. When the motorcycle has been out of operation for more than a week, it is therefore recommended to drain the old fuel from the float chamber. The engine will immediately start off when the float chamber is filled with new fuel. Fuel supply interrupted Loosen fuel hose at carburettor, lead into a basin and open fuel tap – if fuel leaks out, the carburetor might need cleaning – if no fuel leaks out, check tank ventilation, i.e. clean fuel tap Flooded engine Fully open the throttle when starting or exchange the spark plug, respectively Sooty or wet spark plug Clean and dry the spark plug or exchange it, respectively Electrode gap too large Adjust spark plug electrode gap to 0,7 mm Spark plug connector or spark plug faulty Dismount spark plug, connect ignition cable, hold to ground (blank place on engine) and actuate starter, a strong spark must be produced at the spark plug – If no spark is created exchange the spark plug. – If the new spark plug doesn't produce a spark either, disconnect the spark plug connector from the ignition cable, hold it a distance of approx. 5 mm from ground and start. – If a spark now occurs, replace spark plug cap – If no spark is produced, control ignition system The plug connection of the CDIunit, the pulse generator or the ignition coil has oxydized Remove the seat, the right side cover and the fuel tank. Clean the plug connection and treat it with contact spray Water in carburetor or jets blocked Dismount and clean carburetor Engine doesn’t crank. 9-8D Engine fails to idle Engine does not rev high Art.-Nr. 3.206.006 -E Engine will not reach full power Repair manual KTM LC4 Engine overheats High oil consumption REMEDY CAUSE TROUBLE Glogged idling jet Disassemble carburetor and clean jets Uncorrect adjustment of adjusting screws on carburetor Adjust carburetor Defective spark plug Replace spark plug Defective ignition system Check ignition system Carburetor fuel level too high because Dismount carburetor and check if worn out Float needle is dirty or worn out Replace float needle Float leaks Replace float The cold starting system is permanently activated due to a lack of play in the choke cable. Adjust choke cable. Defective membrane of slide (640) Replace membrane Loose carburettor jets Tighten jets Electronic ignition timing faulty Check pulse generator and ignition system Fuel supply partically interrupted or carburetor dirty Clean and check fuel system as well as carburetor Float leaks Replace the float Defective membrane of slide (640) Replace membrane Air filter very dirty Clean or replace air filter Valve clearance to small Adjust valve clearance Loss of compression because hand decompressor has no play Check setting of the hand decompression cable Electronic ignition timing faulty Check pulse generator and ignition system Insufficient cooling liquid Refill cooling liquid (see maintenace work), check cooling system for leaks Radiator fins are extremely dirty Clean radiator with water jet Foam forms in cooling system Replace cooling liquid, use antifreezer with brand name Bent cooling hose Shorten or replace cooling hose Thermostat defective Remove and check thermostat (opening temperature 70°C (158°F) or replace it. Blown fan fuse Replace fuse and check if fan operates properly (see below) Defect thermo switch Replace thermo switch Fan defective Check if fan operates properly. To do this, start the engine, then bypass the connections to the thermo switch (bottom right radiator). Buckling gear ventilation hose Readjust or replace ventilation hose Engine oil level too high Check engine oil level when the engine is warm; correct if necessary Engine oil too thin (viscosity) Use thicker engine oil; see chapter „Engine oil“ 9-9D REMEDY CAUSE TROUBLE All switched on lamps blown out Voltage regulator faulty Remove seat and check connections. Check voltage regulator Headlight light fail parking Blown fuse Replace fuse (below the headlight mask). Flasher lights, brake light, fan and horn fail Blown fuse Replace fuse (below the headlight mask). The NEUTRAL lamp is not on even though the gear is in NEUTRAL Defect indicator lamp. Replace indicator lamp Defect neutral switch. Connect cable to ground; neutral switch must be replaced if indicator lamp lights up. Loose connections, defect cable. Check connections and cables. The ignition (power consumer) hasn’t been switched off Recharge the battery according to the relevant instructions. The battery isn’t charged by the generator Remove seat and check voltage regulator connections; Check voltage regulator and generator. and The battery is discharged 10-1D TECHNICAL SPECIFICATIONS Repair manual KTM LC4 Art.-Nr. 3.206.006 -E INDEX MODEL 1998 TECHNICAL SPECIFICATIONS TECHNICAL SPECIFICATIONS TECHNICAL SPECIFICATIONS TECHNICAL SPECIFICATIONS TECHNICAL SPECIFICATIONS TECHNICAL SPECIFICATIONS TECHNICAL SPECIFICATIONS TECHNICAL SPECIFICATIONS TECHNICAL SPECIFICATIONS TECHNICAL SPECIFICATIONS – – – – – – – – – – ENGINE 400/540 SXC . . . . . . . . . . . . . .10-3 CHASSIS 400/540 SXC . . . . . . . . . . . . . .10-5 ENGINE 400/620 SX, SC . . . . . . . . . . . . .10-6 CHASSIS 400/620 SX, SC . . . . . . . . . . . .10-8 ENGINE 620 LC4 COMPETITION . . . . . .10-9 CHASSIS 620 LC4 COMPETITION . . . . .10-11 ENGINE 400/540 SXC . . . . . . . . . . . . . .10-12 CHASSIS 400/640 LC4 . . . . . . . . . . . . .10-15 CHASSIS 640 ADVENTURE-R . . . . . . . .10-16 CHASSIS 640 DUKE-E . . . . . . . . . . . . . .10-17 MODEL 1999 TECHNICAL SPECIFICATIONS TECHNICAL SPECIFICATIONS TECHNICAL SPECIFICATIONS TECHNICAL SPECIFICATIONS TECHNICAL SPECIFICATIONS TECHNICAL SPECIFICATIONS TECHNICAL SPECIFICATIONS TECHNICAL SPECIFICATIONS TECHNICAL SPECIFICATIONS TECHNICAL SPECIFICATIONS TECHNICAL SPECIFICATIONS TECHNICAL SPECIFICATIONS – – – – – – – – – – – – ENGINE 400/540 SXC, 620 SX . . . . . . . 10-18 CHASSIS 400/540 SXC, 620 SX . . . . . . 10-20 ENGINE 400/620 SC . . . . . . . . . . . . . . 10-21 CHASSIS 400/620 SC . . . . . . . . . . . . . 10-23 ENGINE 620 LC4 COMPETITION . . . . . 10-24 CHASSIS 620 LC4 COMPETITION . . . . 10-26 ENGINE 400/640 LC4 . . . . . . . . . . . . . .10-27 CHASSIS 400/640 LC4 . . . . . . . . . . . . .10-29 ENGINE 640 ADVENTURE-R . . . . . . . . .10-30 CHASSIS 640 ADVENTURE-R . . . . . . . .10-32 ENGINE 640 DUKE . . . . . . . . . . . . . . . .10-33 CHASSIS 640 DUKE . . . . . . . . . . . . . . .10-35 MODEL 2000 TECHNICAL SPECIFICATIONS TECHNICAL SPECIFICATIONS TECHNICAL SPECIFICATIONS TECHNICAL SPECIFICATIONS TECHNICAL SPECIFICATIONS TECHNICAL SPECIFICATIONS TECHNICAL SPECIFICATIONS TECHNICAL SPECIFICATIONS TECHNICAL SPECIFICATIONS – – – – – – – – – ENGINE SC, SUPERMOTO . . . . . . . . . . 10-36 CHASSIS SC, SUPERMOTO . . . . . . . . . 10-38 ENGINE LC4-E, ADVENTURE, DUKE . . .10-39 CHASSIS LC4-E SUPERMOTO . . . . . . . .10-41 CHASSIS 640 ADVENTURE-R . . . . . . . .10-42 CHASSIS 640 DUKE . . . . . . . . . . . . . . .10-43 CHASSIS 640 DUKE AUS . . . . . . . . . . .10-44 ENGINE 400 SXC . . . . . . . . . . . . . . . . . 10-45 CHASSIS 400/540 SXC . . . . . . . . . . . . .10-46 10 10-2D INDEX Art.-Nr. 3.206.006 -E MODEL 2001 TECHNICAL SPECIFICATIONS TECHNICAL SPECIFICATIONS TECHNICAL SPECIFICATIONS TECHNICAL SPECIFICATIONS TECHNICAL SPECIFICATIONS TECHNICAL SPECIFICATIONS TECHNICAL SPECIFICATIONS – – – – – – – ENGINE 620 SC, SUPERMOTO . . . . . . 10-47 CHASSIS 620 SC, SUPERMOTO . . . . . . 10-49 ENGINE LC4-E, ADVENTURE, DUKE . . .10-50 CHASSIS LC4-E, SUPERMOTO . . . . . . .10-52 CHASSIS 640 LC4 ADVENTURE . . . . . .10-53 CHASSIS 640 DUKE . . . . . . . . . . . . . . .10-54 CHASSIS 640 DUKE USA, AUS . . . . . . .10-55 MODELL 2002 TECHNICAL SPECIFICATIONS – ENGINE 625 SC, SUPERMOTO . . . TECHNICAL SPECIFICATIONS – CHASSIS 625 SC, SUPERMOTO . . . TECHNICAL SPECIFICATIONS – ENGINE 640 LC4, ADVENTURE, DUKE TECHNICAL SPECIFICATIONS – CHASSIS 640 LC4, SUPERMOTO . . TECHNICAL SPECIFICATIONS – CHASSIS 640 ADVENTURE . . . . . . TECHNICAL SPECIFICATIONS – CHASSIS 640 DUKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-56 10-57 10-58 10-59 10-60 10-61 MODELL 2003 TECHNICAL SPECIFICATIONS – ENGINE 625 SXC . . . . . . . . . . . . . . TECHNICAL SPECIFICATIONS – CHASSIS 625 SXC . . . . . . . . . . . . . TECHNICAL SPECIFICATIONS – ENGINE 640 LC4, ADVENTURE, DUKE TECHNICAL SPECIFICATIONS – CHASSIS 640 LC4, SUPERMOTO . . TECHNICAL SPECIFICATIONS – CHASSIS 640 LC4 ADVENTURE . . . TECHNICAL SPECIFICATIONS – CHASSIS 640 DUKE . . . . . . . . . . . . TECHNICAL SPECIFICATIONS – ENGINE 660 SMC . . . . . . . . . . . . . TECHNICAL SPECIFICATIONS – CHASSIS 660 SMC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-62 10-63 10-64 10-65 10-66 10-67 10-68 10-69 Repair manual KTM LC4 TIGHTENING TORQUES ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-70 CHASSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-71 ASSEMBLY CLEARANCE, WEAR LIMIT . . . . . . . . . . . . . . . . . . . . . . . . .10-72 Generator Spark plug Spark plug gap Cooling system Cooling liquid Starting equipment Ignition system Ignition timing Engine Design Displacement Bore / Stroke Ratio Fuel Valve timing Camshaft Valve timing by 1 mm valve clearence Valve diameter Valve clearence cold Crank shaft bearing Connecting rod bearing Top end bearing Piston Piston rings Engine lubrication Engine oil Engine oil quantity Primary ratio Clutch Transmission Gear ratio Art.-Nr. 3.206.006 -E 400 LC4 540 LC4 Liquid-cooled single cylinder 4-stroke engine with and without balancer shaft 398 cm3 538,5 cm3 89 / 64 mm 95 / 76 mm 10,8 : 1 11,1 : 1 unleaded premium gasoline with a least RON 95 4 valves over rocker arm and 1 overhead camshaft, camshaft drive through single chain 249° (249/1) IO 22° BTDC EO 60° BBDC IO 13° BTDC EO 53° BBDC IC 42° ABDC EC 4° ATDC IC 51° ABDC EC 11° ATDC Intake: 36 mm Exhaust: 30 mm Intake: 0,20 mm Exhaust: 0,20 mm Intake: 0,15 mm Exhaust: 0,15 mm 2 cylinder roller bearing needle bearing bronze bushing forged/cast aluminium alloy 1 compression ring, 1 taper face ring, 1 oil scraper ring forced-feed lubrication through two Eaton-Oilpumps with oil sump see bellow # 1,40liters straight geared spur wheels 30 : 81 teeth multi disc clutch in oil bath 5-speed claw shifted 1st 14:35 2nd 15:24 3rd 18:21 4th 20:19 5th 22:18 contactless thyristor ignition with electronic advanced system type SEM 400 SXC : adjustment to max. 38 ° BTDC at 6000 rpm 540 SXC: adjustment to max. 32 ° BTDC at 6000 rpm 12V 130W NGK D8EA 0,6 mm liquid cooled, permanent rotation of cooling liquid through mechanic driven water pump 1 liter, 40% antifreeze, 60% water, at least –25 ° C (–13 ° F) decompressor automatic and hand actuated, cold and hot start knob on carburetor TECHNICAL SPECIFICATIONS – ENGINE Repair manual KTM LC4 axial play.......................................0,03 - 0,12 mm (0,001-0,005 in) run out of crank stud ......................max. 0,04 mm (0,0016 in) Connecting rod bearing radial play .......................................max. 0,05 mm (0,0019 in) axial play.........................................max. 1,00 mm (0,04 in) Piston assembly clearance 400/540/620 ...max. 0,12 mm (0,005 in) Piston rings end gap compression rings............................max. 0,60 mm (0,023 in) oil scraper ring ................................max. 0,80 mm (0,031 in) Valves seat sealing intake...........................max. 1,50 mm 0,059 in) seat sealing exhaust ........................max. 2,00 mm (0,079 in) run out of valve heads ....................max. 0,03 mm (0,001 in) valve guides diameter .....................max. 7,05 mm (0,277 in) Oil pump clearance outer rotor - housing .......max. 0,20 mm (0,008 in) clearance outer rotor - inner rotor...max. 0,20 mm (0,008 in) Bypaß valve minimum spring lenght ...............................25 mm (1 in) Clutch discs wear limit organic ......................................2,5 mm (0,1 in) Transmission shafts axial play...........................................0,1 - 0,4 mm (0,004 in) Clutch minimum clutchspring lenght .........34,5 mm (new 37 mm)(1,36 in - new 1,45 in) Crank shaft TOLERANCE, ASSEMBLY CLEARANCE 400/540 SXC ‘98 10-3D M18x1,5 M12x1,5 Hexagon nut for inner clutch hub Kickstarter stop bolt 60 Nm (44 ft.lb) 20 Nm (15 ft.lb) M6x50/M6x55 (12.9) M6x65/M6x70 (8.8) M10 M10 M10 M22x1,5 M12x1,5 M12x1,5 M8x1 M10x1 M8x1 M12x1,5 M7x0,75 M12 AH bolt cylinder head top sect. AH bolt cylinder head top sect. Cylinder head bolts Collar nuts at cylinder base Hexagon bolt chain sprocket Oil drain plug Magnetic plug Plug bypass valve Banjo bolts oil lines Banjo bolt oil lines Jet screw clutch cover Bolt plug timing-chain tensioner Counternuts valve adjusting screws Spark Plug Carburetor Carburetor setting number Main jet Needle jet Idling jet Jet needle Needle position from top Mixture.adju. screw open Throttle valve Starting jet Performance restrictor (6 ft.lb) (6 ft.lb) (7 ft.lb) (7 ft.lb) 400 SXC (20 kW) PHM 38 ND 120198 140 AB 265 50 K 32 II 1,5 turn 50/1 45 slide stop 56mm PHM 38 ND 120198 140 AB 265 50 K 32 II 1,5 turn 50/1 45 – 540 SXC VHSB 38 QS 081297 185 FN 260 33 K 32 II 1,5 turn 50 40 – 20 Nm (15 ft.lb) 10 Nm 15 Nm (11 ft.lb) 10 Nm 20 Nm (15 ft.lb) 20 Nm (15 ft.lb) 30 Nm (22 ft.lb) Loctite 243 + 40 Nm (30 ft.lb) 40 Nm (30 ft.lb) 50 Nm (37 ft.lb) 8 Nm 20 Nm (15 ft.lb) 8 Nm 400 SXC BASIC CARBURETOR SETTING 20 Nm (15 ft.lb) M6x25 (6 ft.lb) AH bolt cylinder head top sect. Loctite 243 + 8 Nm Hexagon bolt camshaft gear Loctite 243 + 35 Nm (26 ft.lb) M6 M10 AH bolts oil pump 50 Nm (37 ft.lb) Loctite 243 + 80 Nm (59 ft.lb) M12x1 LH thread Collar nut flywheel Loctite 243 + 170 Nm (125 ft.lb) M20x1,5 TIGHTENING TORQUES - ENGINE Hexagon nut at primary gear 10W 40 10W 50 10W 60 – 15W 40 15W 50 15W 60 + CAUTION ! OIL QUALITY OR MINOR QUANTITY EFFECT EARLY ENGINE-WEAR. POOR ! Use only oil brands, which meet quality requirements of API-classes SF, SG or SH (informations on bottles) or higher. Both, mineral and synthetic oils with above specifications can be used. 32°F 0°C TEMPERATURE API: SF, SG, SH Engine oil VHSB 38 QS 091297 140 (185) FN 260 33 K 32 II 1,5 turn 50 40 slide stop 36mm 540 SXC (20 kW) # 10-4D 540:15:50 540: 122 kg (269 lbs) 350 mm (13,8 in) Ground clearance 400: 121 kg (267 lbs) 940 mm (37 in) Seat high Dead weight without fuel 1510 ± 10 mm (59,4 ± 0,4 in) 62,5° /8 x 1/4" O-Ring 5 400: 14:50 Wheel base Steering angle Chain Final drive ratio 9 liter (3 US gallons) of that 1,5 liter (0,4 US gallons) reserve 140/80 - 18 1,2 bar (17 psi) 2,0 bar (28 psi) – Tyres rear Air pressure offroad Air press. road, driver only Air press. road with passenger Fuel tank capacity 90/90 - 21 1,0 bar (14 psi) 1,5 bar (21 psi) – Disc brake with carbon-steel brake disc Ø 220 mm (8,7 in), brake caliper floated brake disc Ø = 260 mm (10,2 in) Disc brake with carbon-steel brake disc , brake caliper floated Central shock absorber (WP) with PRO-LEVER linkage to rear-swingarm with needle bearing Tyres front Air pressure offroad Air press. road, driver only Air press. road with passenger Rear brake Front brake Rear suspension 285/320 mm (11,2/12,6 in) WP Extreme Fork 400/540 SXC Central chrome-moly-steel frame Frame Wheel travel front/rear Art.-Nr. 3.206.006 -E SAE 5 ca 800 ccm 155 mm 7 mm 4,2 N/mm 12 12 WP 09.18.S7.44 M 10 M8 M 20x1,5 M 14x1,5 M8 M8 M8 M6 M8 M 10 Collar bolt front axle Brake caliper front Collar nut rear axle Hex. nut swing arm bolt Clamping bolt top triple clamp Clamping bolt bottom triple clamp Clamping bolts fork leg axle passage Other bolts chassis TORQUES 40 Nm 10 Nm 25 Nm 45 Nm 10 Nm 20 Nm 15 Nm 100 Nm 80 Nm Loctite 243 + 25 Nm 23 mm Spring preload 4 63/260 Rebound adjuster Spring 3 Compression adjuster WP 01.18.Q7.82 (7,4 ft.lb) (18 ft.lb) (33 ft.lb) (7,4 ft.lb) (15 ft.lb) (11 ft.lb) (74 ft.lb) (59 ft.lb) (18 ft.lb) (30 ft.lb) STANDARD-ADJUSTMENT - SHOCK ABSORBER NOTE FOR WHITE POWER FORKS: The damping units in the left and the right fork leg are of different design. Make sure not to mix them up in case of repair or service works. Fork oil Capacity per fork leg Air chamber length Spring preload Spring Rebound adjuster Compression adjuster STANDARD ADJUSTMENT - FORK TECHNICAL SPECIFICATIONS - CHASSIS 400/540 SXC ‘98 Repair manual KTM LC4 10-5D Generator Spark plug Spark plug gap Cooling system Cooling liquid Starting equipment Ignition system Ignition timing Engine Design Displacement Bore / Stroke Ratio Fuel Valve timing Camshaft Valve timing by 1 mm valve clearence Valve diameter Valve clearence cold Crank shaft bearing Connecting rod bearing Top end bearing Piston Piston rings Engine lubrication Engine oil Engine oil quantity Primary ratio Clutch Transmission Gear ratio 400 LC4 620 LC4 Liquid-cooled single cylinder 4-stroke engine with balancer shaft 398 cm3 609 cm3 89 / 64 mm 101 / 76 mm 10,8 : 1 SX: 11,5 : 1 SC: 10,4 : 1 unleaded premium gasoline with a least RON 95 4 valves over rocker arm and 1 overhead camshaft, camshaft drive through single chain 249° (249) IO 22° BTDC EO 59° BBDC IO 14° BTDC EO 56° BBDC IC 47° ABDC EC 10° ATDC IC 55° ABDC EC 13° ATDC Intake: 36 mm Exhaust: 30 mm Intake: 0,20 mm Exhaust: 0,20 mm Intake: 0,15 mm Exhaust: 0,15 mm 2 cylinder roller bearing needle bearing bronze bushing forged/cast aluminium alloy 1 compression ring, 1 taper face ring, 1 oil scraper ring forced-feed lubrication through Eaton-Oilpump with oil sump see bellow # 1,40 liters straight geared spur wheels 30 : 81 teeth multi disc clutch in oil bath 5-speed claw shifted 1st 14:35 2nd 15:24 3rd 18:21 4th 20:19 5th 22:18 contactless thyristor ignition with electronic advanced system type SEM adjustment to max. 38 ° BTDC at 6000 rpm SX: adjustment to max. 38 ° BTDC at 6000 rpm SC: adjustment to max. 32 ° BTDC at 6000 rpm 12V 130W NGK D8EA 0,6 mm liquid cooled, permanent rotation of cooling liquid through mechanic driven water pump 1 liter, 40% antifreeze, 60% water, at least –25 ° C (–13 ° F) decompressor automatic and hand actuated, cold and hot start knob on carburetor TECHNICAL SPECIFICATIONS – ENGINE Hexagon nut at primary gear Collar nut flywheel Hexagon nut for inner clutch hub Kickstarter stop bolt AH bolts oil pump Hexagon bolt camshaft gear AH bolt cylinder head top sect. AH bolt cylinder head top sect. AH bolt cylinder head top sect. Cylinder head bolts Collar nuts at cylinder base Hexagon bolt chain sprocket Oil drain plug Magnetic plug Plug bypass valve Banjo bolts oil lines Banjo bolt oil lines Jet screw clutch cover Bolt plug timing-chain tensioner Counternuts valve adjusting screws Spark plug M20x1,5 Loctite 243 + 170Nm M12x1 LH thread 60 Nm M18x1,5 Loctite 648 + 80 Nm M12x1,5 70 Nm M6 Loctite 243 + 8 Nm M10 35 Nm M6x25 8 Nm M6x50/M6x55 (12.9) 20 Nm M6x65/M6x70 (8.8) 8 Nm M10 50 Nm M10 40 Nm M10 Loctite 243 + 40 Nm M22x1,5 30 Nm M12x1,5 20 Nm M12x1,5 20 Nm M8x1 10 Nm M10x1 15 Nm M8x1 10 Nm M12x1,5 20 Nm M7x0,75 20 Nm M12 20 Nm TIGHTENING TORQUES - ENGINE (125 (44 (59 (52 (6 (26 (6 (15 (6 (37 (30 (30 (22 (15 (15 (7 (11 (7 (15 (15 (15 ft.lb) ft.lb) ft.lb) ft.lb) ft.lb) ft.lb) ft.lb) ft.lb) ft.lb) ft.lb) ft.lb) ft.lb) ft.lb) ft.lb) ft.lb) ft.lb) ft.lb) ft.lb) ft.lb) ft.lb) ft.lb) Piston assembly clearance 400/620 ...........max. 0,12 mm (0,005 in) Piston rings end gap compression rings............................max. 0,60 mm (0,023 in) oil scraper ring ................................max. 0,80 mm (0,031 in) Valves seat sealing intake...........................max. 1,50 mm 0,059 in) seat sealing exhaust ........................max. 2,00 mm (0,079 in) run out of valve heads ....................max. 0,03 mm (0,001 in) valve guides diameter .....................max. 7,05 mm (0,277 in) Oil pump clearance outer rotor - housing .......max. 0,20 mm (0,008 in) clearance outer rotor - inner rotor...max. 0,20 mm (0,008 in) Bypaß valve minimum spring lenght ...............................25 mm (1 in) Clutch discs wear limit organic ......................................2,5 mm (0,1 in) Transmission shafts axial play...........................................0,1 - 0,4 mm (0,004 in) Clutch minimum clutchspring lenght .........34,5 mm (new 37 mm)(1,36 in - new 1,45 in) axial play.......................................0,03 - 0,12 mm (0,001-0,005 in) run out of crank stud ......................max. 0,04 mm (0,0016 in) Connecting rod bearing radial play .......................................max. 0,05 mm (0,0019 in) axial play.........................................max. 1,00 mm (0,04 in) Crank shaft TOLERANCE, ASSEMBLY CLEARANCE 400/620 SX, SC ‘98 10-6D # – 15W 40 15W 50 15W 60 + ! CAUTION ! OIL QUALITY OR MINOR QUANTITY EFFECT EARLY ENGINE-WEAR. POOR Use only oil brands, which meet quality requirements of API-classes SF, SG or SH (informations on bottles) or higher. Both, mineral and synthetic oils with above specifications can be used. 32°F 0°C TEMPERATURE 10W 40 10W 50 10W 60 Engine oil PHM 38 SD 4894/6 190 DR 270 45 K 51 2 nd 1,5 turn 40 45 – PHM 38 SD 300896 150 DR 266 45 K 51 3 rd 1,5 turn 40 45 slide stop 22 mm API: SF, SG, SH Carburetor Carburetor setting number Main jet Needle jet Idling jet Jet needle Needle position from top Mixture.adju. screw open Throttle valve Starting jet Performance restrictor 400 SC 400 SC (20 kW) BASIC CARBURETOR SETTING Repair manual KTM LC4 PHM 40 SD 4922 195 DR 272 45 K 51 2 nd 1,5 turn 40 45 – 620 SX 620 SC PHM 40 SD 110996 155 DR 268 45 K 51 3 rd 1,5 turn 40 45 slide stop 26 mm 620 SC (20 kW) Art.-Nr. 3.206.006 -E 10-7D 62,5° Steering angle 350 mm (13,8 in) Ground clearance 211 kg (466 lbs) 335 kg (737 lbs) 350 kg (770 lbs) Max. permissible front axle load Max. permissible rear axle load Max. permissible laden weight 400 : 121 kg (267 lbs) 620 : 122 kg (269 lbs) 940 mm (37 in) Seat high Dead weight without fuel 1510 ± 10 mm (59,4 ± 0,4 in) Wheel base 115 kg (254 lbs) /8 x 1/4" 5 14:48, 14:50, 15:40, 15:45, 15:48 15:50, 16:40, 16:45 Chain Final drive ratio 140/80-18 70R 1,2 bar (17 psi) 2,0 bar (28 psi) 90/90-21 1,0 bar (14 psi) 1,5 bar (21 psi) 9 liter (3 US gallons) of that 1,5 liter (0,4 US gallons) reserve 110/90-19 1,2 bar (17 psi) – Tyres rear Air pressure offroad Air press. road, driver only Fuel tank capacity 80/100-21 1,0 bar (14 psi) – Disc brake with carbon-steel brake disc Ø 220 mm (8,7 in), brake caliper floated Rear brake Tyres front Air pressure offroad Air press. road, driver only Disc brake with carbon-steel brake disc , brake caliper floated brake disc Ø = 260 mm (10,2 in) Central shock absorber (WP) with PRO-LEVER linkage to rear-swingarm with needle bearing 400/620 SC Front brake Rear suspension 285/320 mm (11,2/12,6 in) WP Extreme Fork Wheel travel front/rear Central chrome-moly-steel frame Frame 620 SX 8 SAE 5 SAE 5 ca 800 ccm 155 mm 7 mm 4,2 N/mm 12 12 WP 09.18.S7.44 M 20x1,5 M 14x1,5 M 8 (Extreme) M8 (USD) M 8 (Extreme) M8 (USD) M 7/M8 M6 M8 M10 Hex. nut swing arm bolt Clamping bolt top triple clamp Clamping bolt bottom triple clamp Clamping bolts fork leg axle passage Other bolts chassis M8 Brake caliper front 15 Nm 15 Nm 100 Nm 80 Nm 20 Nm 15 Nm (19 ft.lb) (30 ft.lb) 10 Nm 25 Nm 45 Nm (7 ft.lb) (19 ft.lb) (33 ft.lb) (5/7 ft.lb) (15 ft.lb) (11 ft.lb) (11 ft.lb) (11 ft.lb) (74 ft.lb) (59 ft.lb) + Loctite 243 25 Nm 40 Nm 7/10 Nm 23 mm 66/260 4 3 WP 01.18.Q7.81 Collar nut rear axle M 10 23 mm 63/260 4 3 Collar bolt front axle TORQUES Spring preload Spring Rebound adjuster Compression adjuster WP 01.18.Q7.82 STANDART-ADJUSTMENT - SHOCK ABSORBER NOTE FOR WHITE POWER FORKS: The damping units in the left and the right fork leg are of different design. Make sure not to mix them up in case of repair or service works. Fork oil 140 mm ca 800 ccm Capacity per fork leg 8 mm 4,4 N/mm 12 Air chamber length Spring preload Spring Rebound adjuster Compression adjuster WP 09.18.S7.40 STANDARD ADJUSTMENT - FORK TECHNICAL SPECIFICATIONS - CHASSIS 400 / 620 SX, SC ‘98 10-8D Ignition system Ignition timing Generator Spark plug Spark plug gap Cooling system Cooling liquid Starting equipment Engine Design Displacement Bore / Stroke Ratio Fuel Valve timing Camshaft Valve timing by 1 mm valve clearence Valve diameter Valve clearence cold Crank shaft bearing Connecting rod bearing Top end bearing Piston Piston rings Engine lubrication Engine oil Engine oil quantity Primary ratio Clutch Transmission Gear ratio Art.-Nr. 3.206.006 -E 620 LC4 COMP. Liquid-cooled single cylinder 4-stroke engine with balancer shaft 609 cm3 101 / 76 mm 10,4 : 1 unleaded premium gasoline with a least RON 95 4 valves over rocker arm and 1 overhead camshaft, camshaft drive through single chain 249° (249/1) IO 15° BTDC EO 52° BBDC IC 54° ABDC EC 17° ATDC Intake: 36 mm Exhaust: 30 mm Intake: 0,15 mm Exhaust: 0,15 mm 2 cylinder roller bearing needle bearing bronze bushing forged/cast aluminium alloy 1 compression ring, 1 taper face ring, 1 oil scraper ring forced-feed lubrication through Eaton-Oilpump with oil sump see bellow # 2,1 liters including frame straight geared spur wheels 30 : 81 teeth multi disc clutch in oil bath 5-speed claw shifted 1st 14:35 2nd 15:24 3rd 18:21 4th 20:19 5th 22:18 contactless thyristor ignition with electronic advanced system type SEM adjustment to max. 32 ° BTDC at 6000 rpm 12V 130W NGK DR8EA 0,7 mm liquid cooled, permanent rotation of cooling liquid through mechanic driven water pump 1 liter, 40% antifreeze, 60% water, at least –25 ° C (–13 ° F) decompressor automatic and hand actuated, cold and hot start knob on carburetor TECHNICAL SPECIFICATIONS – ENGINE Repair manual KTM LC4 Piston assembly clearance .........................max. 0,12 mm (0,005 in) Piston rings end gap compression rings............................max. 0,60 mm (0,023 in) oil scraper ring ................................max. 0,80 mm (0,031 in) Valves seat sealing intake...........................max. 1,50 mm 0,059 in) seat sealing exhaust ........................max. 2,00 mm (0,079 in) run out of valve heads ....................max. 0,05 mm (0,002 in) valve guides diameter .....................max. 7,05 mm (0,277 in) Oil pump clearance outer rotor - housing .......max. 0,20 mm (0,008 in) clearance outer rotor - inner rotor...max. 0,20 mm (0,008 in) Bypaß valve minimum spring lenght ...............................25 mm (1 in) Clutch discs wear limit organic ......................................2,5 mm (0,1 in) Transmission shafts axial play...........................................0,1 - 0,4 mm (0,004 in) Clutch minimum clutchspring lenght .........34,5 mm (new 37 mm)(1,36 in - new 1,45 in) axial play.......................................0,03 - 0,12 mm (0,001-0,005 in) run out of crank stud ......................max. 0,08 mm (0,0031 in) Connecting rod bearing radial play .......................................max. 0,05 mm (0,0019 in) axial play.........................................max. 1,00 mm (0,04 in) Crank shaft ASSEMBLY CLEARANCE, WEAR LIMIT 620 LC4 COMPETITION ‘98 10-9D Carburetor Carburetor setting number Main jet Needle jet Idling jet Jet needle Needle position from top Mixture.adju. screw open Throttle valve Starting jet Performance restrictor PHM 40 SD 110996 155 DR 268 45 K 51 3 rd 1,5 turn 40 45 slide stop 26 mm 620 LC4 COMP. BASIC CARBURETOR SETTING M6x50/M6x55 (12.9) 20 Nm (15 ft.lb) M6x65/M6x70 (8.8) 8 Nm (6 ft.lb) M10 50 Nm (37 ft.lb) M10 40 Nm (30 ft.lb) M10 Loctite 243 + 40 Nm (30 ft.lb) M22x1,5 30 Nm (22 ft.lb) M12x1,5 20 Nm (15 ft.lb) M12x1,5 20 Nm (15 ft.lb) M8x1 10 Nm (7 ft.lb) M10x1 15 Nm (11 ft.lb) M8x1 10 Nm (7 ft.lb) M12x1,5 20 Nm (15 ft.lb) M7x0,75 20 Nm (15 ft.lb) M 12 20 Nm (15 ft.Ib) ft.lb) ft.lb) ft.lb) ft.lb) ft.lb) ft.lb) ft.lb) AH bolt cylinder head top sect. AH bolt cylinder head top sect. Cylinder head bolts Collar nuts at cylinder base Hexagon bolt chain sprocket Oil drain plug Magnetic plug Plug bypass valve Banjo bolts oil lines Banjo bolt oil lines Jet screw clutch cover Bolt plug timing-chain tensioner Counternuts valve adjusting screws Spark plug (125 (44 (59 (37 (6 (26 (6 M20x1,5 Loctite 243 +170Nm M12x1 LH thread 60 Nm M18x1,5 Loctite 243 + 80 Nm M12x1,5 50 Nm M6 Loctite 243 + 8 Nm M10 Loctite 243 + 35 Nm M6x25 8 Nm TIGHTENING TORQUES - ENGINE Hexagon nut at primary gear Collar nut flywheel Hexagon nut for inner clutch hub Kickstarter stop bolt AH bolts oil pump Hexagon bolt camshaft gear AH bolt cylinder head top sect. # – 10W 40 10W 50 10W 60 0°C 32°F 15W 40 15W 50 15W 60 + ! CAUTION ! OIL QUALITY OR MINOR QUANTITY EFFECT EARLY ENGINE-WEAR. POOR Use only oil brands, which meet quality requirements of API-classes SF, SG or SH (informations on bottles) or higher. Both, mineral and synthetic oils with above specifications can be used. Engine oil TEMPERATURE API: SF, SG, SH 10-10D 10-11D TECHNICAL SPECIFICATIONS - CHASSIS 620 LC4 COMP. ‘98 620 LC4 COMP. Frame Central chrome-moly-steel frame Fork WP Extreme Wheel travel front/rear Rear suspension 280 / 320 mm (11,0 / 12,6 in) Central shock absorber (WP) with PRO-LEVER linkage to rear-swingarm with needle bearing Front brake Disc brake with carbon-steel brake disc , brake caliper floated Rear brake Disc brake with carbon-steel brake disc Ø 220 mm (8,7 in), brake caliper floated brake disc Ø = 300 mm (11,8 in) Tyres front Air press. road, driver only Air press. road with passenger 90/90-21 T63 1,5 bar (21 psi) 2,0 bar (28 psi) Tyres rear Air press. road, driver only Air press. road with passenger 130/80-18 T63 2,0 bar (28 psi) 2,2 bar (31 psi) Fuel tank capacity 12 liter (3,2 US gallons) of that 2,5 liter (0,7 US gallons) res Final drive ratio 16:40 Chain O-ring 5/8 x 1/4" Battery maintenance-free battery 12V 8Ah Steering angle 62,5° 1510 ± 10 mm (59,4 ± 0,4 in) Art.-Nr. 3.206.006 -E Wheel base Seat high 955 mm (37,6 in) Ground clearance 335 mm (13,2 in) Dead weight without fuel 133 kg (293 lbs) Max. permissible front axle load 211 kg (466 lbs) Max. permissible rear axle load 335 kg (737 lbs) Max. permissible laden weight 350 kg (770 lbs) STANDARD-ADJUSTMENT - SHOCK ABSORBER STANDARD ADJUSTMENT - FORK 118 S 701 918 S 757 Compression adjuster 3 Compression adjuster 12 Rebound adjuster 5 Rebound adjuster 12 Spring 66/260 Spring Spring preload 23 mm Spring preload 10 mm Air chamber length 160 mm Capacity per fork leg Fork oil Repair manual KTM LC4 NOTE FOR WP EXTREME FORKS: The damping units in the left and the right fork leg are of different design. Make sure not to mix them up in case of repair or service works. TORQUES Collar bolt front axle M 10 40 Nm (30 ft.lb) Brake caliper front M8 25 Nm (19 ft.lb) + Loctite 243 Collar nut rear axle M 20x1,5 80 Nm (59 ft.lb) Hex. nut swing arm bolt M 14x1,5 100 Nm (74 ft.lb) Clamping bolt top triple clamp M8 15 Nm (11 ft.lb) Clamping bolt bottom triple clamp M8 20 Nm (15 ft.lb) Clamping bolts fork leg axle passage M8 10 Nm (7 ft.lb) Other bolts chassis M6 M8 M10 10 Nm 25 Nm 45 Nm (7 ft.lb) (19 ft.lb) (33 ft.lb) 4,4 N/mm ca. 800 ccm SAE 5 10-12D TECHNICAL DATA – ENGINE 400 / 640 LC4 ‘98 Engine Design 400 LC4 640 LC4 Liquid-cooled single cylinder 4-stroke engine with balancer shaft and electric starter Displacement 398 ccm 624.6 ccm Bore / Stroke 89 / 64 mm 101 / 78 mm 10,8 : 1 11 : 1 Ratio Fuel Valve timing unleaded premium gasoline with a least RON 95 4 valves over rocker arm and 1 overhead camshaft, camshaft drive through single chain Camshaft Valve timing by 1 mm valve clearence 249° (249/1) IO 22° BTDC IC 47° ABDC EO 60° BBDC EC 4° ATDC Valve diameter Valve clearence cold Intake: 36 mm Intake: 0,20 mm EO 53° BBDC IC 51° ABDC EC 11° ATDC Exhaust: 30 mm Exhaust: 0,20 mm Crank shaft bearing IO 13° BTDC 0,15 mm Exhaust: 0,15 mm 2 cylinder roller bearing Connecting rod bearing needle bearing Top end bearing bronze bushing Piston forged/cast aluminium alloy Piston rings 1 compression ring, 1 taper face ring, 1 oil scraper ring Engine lubrication two Eaten-oilpumps Engine oil see bellow # Engine oil quantity appr. 2,1 liters including frame Primary ratio straight geared spur wheels 30 : 81 teeth Clutch multi disc clutch in oil bath Transmission 5-speed claw shifted Ignition system contactless DC-CDI ignition with digital advanced system type KOKUSAN Ignition timing adjustment to max. 38° BTDC at 6000 rpm Generator 12V 200W Spark plug NGK DR8EA Spark plug gap 0,7 mm Cooling system liquid cooled, permanent rotation of cooling liquid through mechanic driven water pump Cooling liquid 1 liter, 40% antifreeze, 60% water, at least –25 ° C (–13 ° F) Starting equipment electric starter and kickstarter ASSEMBLY CLEARANCE, WEAR LIMIT Crank shaft axial play.............................................................................................0,03 - 0,12 mm (0,001-0,005 in) run out of crank stud ............................................................................max. 0,08 mm (0,0031 in) Connecting rod bearing radial play .............................................................................................max. 0,05 mm (0,0019 in) axial play...............................................................................................max. 1,00 mm (0,04 in) Piston assembly clearance ..............................................................................max. 0,12 mm (0,005 in) Piston rings end gap compression rings .................................................................................max. 0,60 mm (0,023 in) oil scraper ring ......................................................................................max. 0,80 mm (0,031 in) seat sealing intake.................................................................................max. 1,50 mm 0,059 in) seat sealing exhaust ..............................................................................max. 2,00 mm (0,079 in) run out of valve heads ..........................................................................max. 0,05 mm (0,002 in) valve guides diameter ...........................................................................max. 7,05 mm (0,277 in) clearance outer rotor - housing .............................................................max. 0,20 mm (0,008 in) clearance outer rotor - inner rotor.........................................................max. 0,20 mm (0,008 in) Bypaß valve minimum spring lenght.....................................................................................25 mm (1 in) Clutch discs wear limit organic ............................................................................................2,5 mm (0,1 in) Transmission shafts axial play.................................................................................................0,1 - 0,4 mm (0,004 in) Clutch minimum clutch spring lenght .................................................34,5 mm (new 37 mm)(1,36 in - new 1,45 in) Valves Oil pump 10-13D TIGHTENING TORQUES - ENGINE Hexagon nut at primary gear M20x1,5 Hexagon nut flywheel M16x1,25 LH thread Loctite 243 + 170Nm (125 ft.lb) Hexagon nut for inner clutch hub M18x1,5 Kickstarter stop bolt M12x1,5 Allen head bolts oil pump M6 Hexagon bolt camshaft gear M10 Loctite 243 + 35 Nm (26 ft.lb) Allen head bolts outer race M6x12/M6x12,5 Loctite 648 + 18 Nm (13 ft.lb) Allen head bolt cylinder head top sect. M6x50/M6x55 (12.9) Allen head bolt cylinder head top sect. M6x25/M6x65/M6x70 (8.8) Cylinder head bolts M10 Collar nuts at cylinder base M10 40 Nm (30 ft.lb) Hexagon bolt chain sprocket M10 Loctite 243 + 40 Nm (30 ft.lb) Oil drain plug M22x1,5 30 Nm (22 ft.lb) Magnetic plug M12x1,5 20 Nm (15 ft.lb) Plug bypass valve M12x1,5 20 Nm (15 ft.lb) Crankshaft locating bolt M8 25 Nm (18 ft.lb) Hollow bolts oil lines M8x1 10 Nm (7 ft.lb) Hollow bolts oil lines M10x1 15 Nm (11 ft.lb) Jet screw clutch cover M8 Bolt plug timing-chain tensioner M12x1,5 150 Nm (110 ft.lb) 80 Nm (59 ft.lb) 50 Nm (37 ft.lb) Loctite 243 + 8 Nm (6 ft.lb) 20 Nm (15 ft.lb) 8 Nm (6 ft.lb) 50 Nm (37 ft.lb) 10 Nm (7 ft.lb) 20 Nm (15 ft.lb) Counternuts valve adjusting screws M7x0,75 20 Nm (15 ft.lb) Engine fastening bolt M8 40 Nm (30 ft.lb) M10 70 Nm (52 ft.lb) Art.-Nr. 3.206.006 -E GEAR RATIOS Primary ratio Transmission 1st gear 2nd gear 3rd gear 4th gear 5th gear 30:81 14:35 15:24 18:21 20:19 22:18 Original final drive ratio Available chain drive sprockets Available final drive sprockets 15:45 16:40 16:42 17:38 15 for chain 16 5 /8 x 1/4" 17 38 40 42 45 48 Engine oil Repair manual KTM LC4 API: SF, SG, SH TEMPERATURE – 10W 40 10W 50 10W 60 0°C 32°F + 15W 40 15W 50 15W 60 for chain 5 /8 x 1/4" Use only oil brands (Shell Advance Ultra 4), which meet quality requirements of API-classes SF, SG or SH (informations on bottles) or higher. Both, mineral and synthetic oils with above specifications can be used. ! POOR CAUTION ! OIL QUALITY OR MINOR QUANTITY EFFECT EARLY ENGINE-WEAR. 10-14D BASIC CARBURETOR SETTING Carburetor Carburetor setting number Main jet Needle jet Idling jet Jet needle Needle position from top Mixture.adju. screw open Throttle valve Starting jet Performance restrictor 400 LC4 25 kW 400 LC4 31 kW PHM 38 ND 100197 130 AR 264 50 K 23 2 nd 1,5 turn 50/1 45 (50, 55) slide stop 51 mm PHM 38 ND 100197 130 AR 264 50 K 23 2 nd 1,5 turn 50/1 45 (50, 55) – BASIC CARBURETOR SETTING Type Carb.-setting number Main jet Needle jet Idling jet Jet needle Needle clip pos. f. top Mixt. adj. screw open Throttle valve Starting jet Performance restrictor 640 DUKE-E 640 ADV.-R 640 DUKE-E 640 ADV.-R 25 kW 37 kW PHM 40 SD 210198 155 DR 268 45 K 51 4. from top 1.5 turns 40 55 slide stop 28mm PHM 40 SD 210198 155 DR 268 45 K 51 4. from top 1,5 turns 40 55 – 640 LC4 640 LC4 25 kW 37 kW BST40-225 080298 142,5 689 X-6 45 6G5 3 rd – – – slide stop 17 mm BST40-225 080298 142,5 689 X-6 45 6G5 3 rd – – – – 10-15D TECHNICAL SPECIFICATIONS - CHASSIS 400 / 640 LC4 ‘98 400/640 LC4 ‘98 Frame Central chrome-moly-steel frame Fork WP Extreme Wheel travel front/rear Rear suspension 280 / 320 mm (11 / 12.6 in) Central shock absorber WP IBS with PRO-LEVER linkage to rear- swing-arm with needle bearing Front brake Disc brake with carbon-steel brake disc 300 mm (11.8 in), brake caliper floated Rear brake Disc brake with carbon-steel brake disc 220 mm (8.7 in), brake caliper floated Tyres front 90/90 - 21 Enduro 3 Air press. road, driver only 1.5 bar (22 psi) Air press. road with passenger 2.0 bar (29 psi) Tyres rear 140/80 - 18 Enduro 3 Air press. road, driver only 2.0 bar (29 psi) Air press. road with passenger 2.2 bar (31 psi) Fuel tank capacity 12 liter (3.2 US gallons), Final drive ratio 2.5 liter (0,6 US gallons) reserve 400 LC4 = 15:45t 640 LC4 = 16:42t Chain O – Ring 5/8 x 1/4" Battery maintenance-free battery 12V 8Ah Steering angle 62,5 ° Art.-Nr. 3.206.006 -E Wheel base 1510 ± 10 mm (59.4 ± 0.4 in) Seat high 955 mm (37.6 in) Ground clearance 355 mm (13.8 in) Dead weight without fuel 136 kg (300 lbs) Max. permissible front axle load 211 kg (465 lbs) Max. permissible rear axle load 335 kg (740 lbs) Max. permissible laden weight 350 kg (773 lbs) STANDARD ADJUSTMENT - FORK STANDARD-ADJUSTMENT - SHOCK ABSORBER 118S701 918S757 Compression adjuster 12 Compression adjuster Rebound adjuster 12 Rebound adjuster Spring Spring preload 10 mm (0,4 in) Air chamber length 160 mm (6,3 in) Capacity per fork leg Spring preload ca 800 ccm Fork oil Repair manual KTM LC4 Spring 4,4 N/mm SAE 5 TORQUES Collar bolt front axle M10 Brake caliper front M8 40 Nm (30 ft.lb) Loctite 243 + 25 Nm (20 ft.lb) Collar nut rear axle M20x1,5 80 Nm (60 ft.lb) Hex. nut swing arm bolt M14x1,5 100 Nm (74 ft.lb) Clamping bolt upper fork bridge M8 25 Nm (11 ft.lb) Clamping bolt lower fork bridge M8 20 Nm (15 ft.lb) Clamping bolts fork stubs M8 10 Nm (7 ft.lb) Other bolts chassis M6 10 Nm (7 ft.lb) M8 25 Nm (20 ft.lb) M10 45 Nm (33 ft.lb) 3 5 66/260 23 mm (0,9 in) 62,5 ° 154kg (340 lbs) 150 kg (331 lbs) 230 kg (507 lbs) 380 kg (839 lbs) Max. permissible front axle load Max. permissible rear axle load Max. permissible laden weight Ground clearance Dead weight without fuel 940 mm (37 in) 320 mm (12,6 in) Seat high 1510 ± 10 mm (59,4 ± 0,4 in) Wheel base Steering angle maintenance-free battery 12V 8Ah Battery 1 O – Ring /8 x /4" 5 16:40 t 3,8 liter (1 US gallons) reserve Chain Final drive ratio 28 liter (7,4 US gallons), 2,2 bar (31 psi) Fuel tank capacity 2,0 bar (29 psi) Air press. road with passenger 140/80 - 18 70R Enduro 3 Air press. road, driver only Tyres rear 2,0 bar (29 psi) Air press. road with passenger 90/90 - 21 54S Enduro 3 Tyres front 1,5 bar (22 psi) Disc brake with carbon-steel brake disc 220 mm (8,7 in), brake caliper floated Air press. road, driver only Disc brake with carbon-steel brake disc 300 mm (11,8 in), brake caliper floated Rear brake Central shock absorber WP IBS with PRO-LEVER linkage to rear- swing-arm with needle bearing Front brake Rear suspension 300 / 320 mm (11,8 / 12,6 in) WP-Extreme Ø 50 mm Fork Wheel travel front/rear Central chrome-moly-steel frame Frame 640 ADVENTURE R SAE5 ca 800 ccm 155 mm (5,9 in) 10 mm (0,4 in) 4,4 N/mm 12 14 09.18.S7.55 M 10 5 10 Nm 25 Nm 45 Nm M8 M8 M6 M8 M10 Clamping bolt lower fork bridge Clamping bolts fork stubs Other bolts chassis 10 Nm 20 Nm 15 Nm 100 Nm M 14x1,5 M8 Clamping bolt upper fork bridge 80 Nm 40 Nm 23 mm (0,9 in) Hex. nut swing arm bolt M 20x1,5 Collar nut rear axle Collar bolt front axle TORQUES Spring preload 70/260 Rebound adjuster Spring 3 Compression adjuster 01.18.R7.97 (33 ft.lb) (19 ft.lb) (7 ft.lb) (7 ft.lb) (15 ft.lb) (11 ft.lb) (74 ft.lb) (59 ft.lb) (30 ft.lb) STANDARD-ADJUSTMENT - SHOCK ABSORBER Fork oil Capacity per fork leg Air chamber length Spring preload Spring Rebound adjuster Compression adjuster STANDARD ADJUSTMENT - FORK TECHNICAL SPECIFICATIONS - CHASSIS 640 ADVENTURE R ‘98 10-16D 10-17D TECHNICAL SPECIFICATIONS - CHASSIS Type 640 DUKE Frame KTM 640 DUKE-E ‘98 last edition Central chrome-moly-steel frame Fork type wheel travel standard adjustment compression standard adjustment rebound fork leg projection upper fork bridge oil capacity per fork leg air chamber lenght Rear suspension WP - 4054 Roma Top adjuster 140 mm (5,5 in) driver only = 14, with passenger = 14 driver only = 14, with passenger = 14 10 mm (0,4 in) appr. 740 ccm (45 cubic in) / SAE 5 100 mm (4 in) WP central shock absorber with PRO-LEVER linkage to rear- swing-arm with needle bearing Shock absorber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . type WP central shock absorber BAVP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . rear wheel travel 170 mm (6.7 in) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . standard adjustment compression driver only = 3, with passenger = 5 driver only = 5, with passenger = 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . standard adjustment rebound ............................................................ spring preload . . . . . . . . . . . . . . driver only = 23 mm (0.9 in),with passenger = 28 mm (1.1 in) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . spring type 70 - 260 Front brake Art.-Nr. 3.206.006 -E Rear brake Disc brake with carbon-steel brake disc Ø 320 mm (12,6 in) and 4-piston brake caliper Disc brake with carbon-steel brake disc Ø 220 mm (8,7 in) and single-piston brake caliper floated Tyres Air pressure rider only Air pressure with passenger Fuel tank capacity front: 120/70 R 17 58H 2.0 bar (29 psi) 2.2 bar (32 psi) 11,3 liter (3 US gallons), out of this 1,5 liter (0,42 US gallons) reserve Final drive ratio 17 : 38 Chain Lamps Battery o-ring 5/8 x 1/4" low beam high beam parking light speedometer, tachometer light indicator lamp stop and taillight flasher H1 12V 55W (socket P14,5s) H1 12V 55W (socket P14,5s) 12V 4W (socket Ba9s) 12V 1,2W (socket W2x4,6d) 12V 1,2W (socket W2x4,6d) 12V 21/5W (socket BaY15d) 12V 10W (socket Ba15s) Repair manual KTM LC4 62,5° 1460 ± 15 mm (57.5 ± 0.6 in) Seat high 860 mm (33.9 in) Ground clearance 250 mm (9.9 in) TORQUES Front axle Rear axle Hex. nut swing arm bolt Clamping bolt upper fork bridge Clamping bolt lower fork bridge AH bolts front brake caliper AH bolt rear brake caliper support Collar nuts chain tension eccentrics Clamping bolts fork stubs Other bolts chassis HS1 12V 35/35W (socket Px43t) HS1 12V 35/55W (socket Px43t) 12V 4W (socket W2.1 9,5D) 12V 1,2W (socket W2x4.6d) 12V 1,2W (socket W2x4.6d) 12V 21/5W (socket BaY15d) 12V 10W (socket Ba15s) maintenance-free battery 12V 8Ah Steering angle Wheel base rear: 160/60 R 17 69H 2.2 bar (32 psi) 2.4 bar (35 psi) M 17 40 Nm (30 ft.lb) M 20x1.5 80 Nm (59 ft.lb) M 14x1.5 100 Nm (74 ft.lb) M8 15 Nm (18 ft.lb) M8 15 Nm (11 ft.lb) M10 40 Nm (30 ft.lb) M10 40 Nm (30 ft.lb) M10 40 Nm (30 ft.lb) M8 15 Nm (11 ft.lb) M6 10 Nm (7 ft.lb) M8 25 Nm (22 ft.lb) M10 45 Nm (33 ft.lb) 10-18D TECHNICAL SPECIFICATIONS – ENGINE Engine Design Displacement Bore / Stroke Ratio Fuel Valve timing Camshaft Valve timing by 1 mm valve clearance Valve diameter Valve clearance cold Crankshaft bearing Conrod bearing Top end bearing Piston Piston rings Engine lubrication Engine oil Engine oil quantity Primary ratio 400 SXC 398 ccm 89 / 64 mm 10,8 : 1 400/540 SXC, 620 SX ‘99 540 SXC Liquid-cooled single cylinder 4-stroke engine 538,5 ccm 620 SX 609 ccm 101 / 76 mm 11,5 : 1 11,3 : 1 unleaded premium gasoline with at least RON 95 4 valves over rocker arm and 1 overhead camshaft, camshaft drive through single chain 249/1 IO 22° BTDC EO 60° BBDC IO 13° BTDC EO 53° BBDC IC 42° ABDC EC 4° ATDC IC 51° ABDC EC 11° ATDC Intake: 36 mm Exhaust: 30 mm Intake: 0,20 mm Exhaust: 0,20 mm Intake: 0,15 mm Exhaust: 0,15 mm 2 cylinder roller bearing needle bearing bronze bushing forged/cast aluminium alloy 1 compression ring, 1 taper face ring, 1 oil scraper ring forced-feed lubrication through 2 Eaten-oilpumps see bellow # 1,45 liters (0,38 US gallons) straight geared spur wheels 30 : 81 teeth Clutch Transmission Gear ratio multi disc clutch in oil bath 5-speed claw shifted 1st 14:35 2nd 15:24 3rd 18:21 4th 20:19 5th 22:18 contactless thyristor ignition with electronic advanced system type SEM 400 SXC/620 SX: adjustment to max. 38 ° BTDC at 6000 rpm 540 SXC: adjustment to max. 32 ° BTDC at 6000 rpm 12V 130W NGK D8EA NGK DPR8 EA-9 0,90 mm liquid cooled, permanent rotation of cooling liquid through mechanic driven water pump 1 liter, 40% antifreeze, 60% water, at least –25°C (–13°F) decompressor automatic and hand actuated, cold and hot start knob on carburetor Ignition system Ignition timing Generator Spark plug Spark plug gap Cooling system Cooling liquid Starting equipment BASIC CARBURETOR SETTING Carburetor Carburetor setting number Main jet Needle jet Idling jet Jet needle Needle position from top Mixture.adju. screw open Throttle valve Starting jet Performance restrictor Pump jet 400 SXC 400 SC (20 kW) 540 SXC 540 SXC (20 kW) 620 SX PHM 38 ND 120198 150 (155) AB 265 52 (50) K 11 I 1,5 turn 50/1 45 – 33 (38) PHM 38 ND 120198 150 (155) AB 265 52 (50) K 11 I 1,5 turn 50/1 45 slide stop 48mm 33 (38) VHSB 38 QS 081297 185 FN 260 (FN 258) 33 K 35 (K 32) II 1,5 turn 50 40 – – VHSB 38 QS 091297 140 (185) FN 260 (FN 258) 33 K 35 (K32) II 1,5 turn 50 40 PHM 40 SD 4922 195 DR 272 45 K 51 II 1,5 turn 40 45 – – slide stop 36mm – 10-19D ASSEMBLY CLEARANCE, WEAR LIMIT Crank shaft Conrod bearing Piston forged Piston cast Piston rings end gap Valves Oil pump Bypaß valve Clutch discs Clutch springs Transmission shafts axial play..................................................0,03 - 0,12 mm run out of crank stud .................................max. 0,08 mm radial play ..................................................max. 0,05 mm axial play ...................................................max. 1,00 mm assembly clearance ...................................max. 0,12 mm assembly clearance ...................................max. 0,05 mm compression rings ......................................max. 0,60 mm oil scraper ring ...........................................max. 0,80 mm seat sealing intake......................................max. 1,50 mm seat sealing exhaust ...................................max. 2,00 mm run out of valve heads ...............................max. 0,03 mm valve guides diameter ................................max. 7,05 mm clearance outer rotor - housing..................max. 0,20 mm clearance outer rotor - inner rotor..............max. 0,20 mm minimum spring length..........................................25 mm wear limit organic .................................................2,5 mm minimum length ...........................34,5 mm (new 37 mm) axial play......................................................0,1 - 0,4 mm (0,001-0,005 in) (0,003 in) (0,002 in) (0,04 in) (0,005 in) (0,002 in) (0,023 in) (0,031 in) 0,059 in) (0,080 in) (0,001 in) (0,277 in) (0,008 in) (0,008 in) (1 in) (0,1 in) (1,36 in - new 1,45 in) (0,004 - 0,016 in) Repair manual KTM LC4 Art.-Nr. 3.206.006 -E TIGHTENING TORQUES - ENGINE Hexagon nut at primary gear Collar nut flywheel Hexagon nut for inner clutch hub Kickstarter stop bolt AH bolts oil pump Hexagon bolt camshaft gear AH bolt cylinder head top sect. AH bolt cylinder head top sect. AH bolt cylinder head top sect. Cylinder head bolts Collar nuts at cylinder base Hexagon bolt chain sprocket Oil drain plug Magnetic plug Plug bypass valve Banjo bolts oil lines Banjo bolt oil lines Jet screw clutch cover Bolt plug timing-chain tensioner Counternuts valve adjusting screws Spark plug Crankshaft locking bolt Engine fastening bolt M M M M M M M M M M M M M M M M M M M M M M M M 20x1,5 12x1 LH thread 18x1,5 12x1,5 6 10 6x25 6x50/M 6x55 (12.9) 6x65/M 6x70 (8.8) 10 10 10 22x1,5 12x1,5 12x1,5 8x1 10x1 8x1 12x1,5 7x0,75 12x1,25 8 8 10 – 0°C 32°F + 15W 40 15W 50 15W 60 (125 ft.lb) (44 ft.lb) (59 ft.lb) (37 ft.lb) (6 ft.lb) (26 ft.lb) (6 ft.lb) (15 ft.lb) (6 ft.lb) (37 ft.lb) (30 ft.lb) (30 ft.lb) (22 ft.lb) (15 ft.lb) (15 ft.lb) (7 ft.lb) (11 ft.lb) (7 ft.lb) (15 ft.lb) (15 ft.lb) (15 ft.Ib) 18 ft.lb) (30 ft.lb) (51 ft.lb) Engine oil Use only oil brands, (Shell Advance Ultra 4) which meet quality requirements of API-classes SF, SG or SH (informations on bottles) or higher. Both, mineral and synthetic oils with above specifications can be used. ! 10W 40 10W 50 10W 60 Nm Nm Nm Nm Nm Nm Nm Nm Nm Nm Nm Nm Nm Nm Nm Nm Nm Nm Nm Nm Nm Nm Nm Nm # API: SF, SG, SH TEMPERATUR Loctite 243 +170 60 Loctite 648 + 80 50 Loctite 243 + 8 Loctite 243 + 35 8 20 8 50 40 Loctite 243 + 40 30 20 20 10 15 10 20 20 20 25 40 70 POOR CAUTION ! OIL QUALITY OR MINOR QUANTITY EFFECT EARLY ENGINE-WEAR. 10-20D TECHNICAL SPECIFICATIONS - CHASSIS 400/540 SXC, 620 SX ‘99 400/540 SXC Frame 620 SX Central chrome-moly-steel frame Fork WP Extreme Wheel travel front/rear 280/320 mm (11/12,6 in) Rear suspension Central shock absorber (WP) with PRO-LEVER linkage to rear-swingarm with needle bearing Front brake Disc brake with carbon-steel brake disc Ø 260 mm (10,2 in), brake caliper floated Rear brake Disc brake with carbon-steel brake disc Ø 220 mm (8,7 in), brake caliper floated Tyres front 90/90-21 54R 80/100-21 51M Air pressure offroad 1,0 bar (14 psi) 1,0 bar (14 psi) Air press. road, driver only – 1,5 bar (21 psi) Tyres rear 140/80-18 70R 110/90-19 62M Air pressure offroad 1,2 bar (17 psi) 1,2 bar (17 psi) Air press. road, driver only 2,0 bar (28 psi) – Fuel tank capacity 9 liter (3 US gallons) of that 1,5 liter (0,4 US gallons) reserve Final drive ratio 400 = 14 : 50, 540 = 15 : 50 15 : 50 Chain 5/8 x 1/4 " Steering angle 62,5° Wheel base 1510 ± 10 mm (59,4 ± 0,4 in) Seat high 940 mm (37 in) Ground clearance 375 mm (14,8 in) Dead weight without fuel 121 kg (267 lbs) STANDARD ADJUSTMENT - FORK STANDARD ADJUSTMENT - SHOCK ABSORBER 09.18.S7.40 09.18.S7.44 Compression adjuster 8 12 Rebound adjuster 12 12 4,4 N/mm 4,2 N/mm 8 mm 7 mm 140 mm 155 mm ca 800 ccm ca 800 ccm SAE 5 SAE 5 Spring Spring preload Air chamber length Capacity per fork leg Fork oil 117 kg (258 lbs) 01.18.S7.98 01.18.Q7.82 Compression adjuster 3 3 Rebound adjuster 5 4 Spring 66/260 63/260 Spring preload 17 mm 23 mm NOTE FOR WHITE POWER FORKS: The damping units in the left and the right fork leg are of different design. Make sure not to mix them up in case of repair or service works. TIGHTENING TORQUES - CHASSIS Collar bolt front axle M 10 40 Nm (30 ft.lb) Brake caliper front M8 Loctite 243 + 25 Nm (18 ft.lb) Collar nut rear axle M 20x1,5 80 Nm (59 ft.lb) Hex. nut swing arm bolt M 14x1,5 100 Nm (74 ft.lb) Clamping bolt top triple clamp M8 15 Nm (11 ft.lb) Clamping bolt bottom triple clamp M8 20 Nm (15 ft.lb) Clamping bolts fork leg axle passage M8 10 Nm (7 ft.lb) Other bolts chassis M6 10 Nm (7 ft.lb) M8 25 Nm (18 ft.lb) M 10 45 Nm (33 ft.lb) 10-21D TECHNICAL SPECIFICATIONS – ENGINE Engine Design Displacement Bore / Stroke Ratio Fuel Valve timing Camshaft Valve timing by 1 mm valve clearance Valve diameter Valve clearance cold Crank shaft bearing Conrod bearing Top end bearing Piston Piston rings Engine lubrication Engine oil Engine oil quantity Primary ratio Repair manual KTM LC4 Art.-Nr. 3.206.006 -E Clutch Transmission Gear ratio Ignition system Ignition timing Generator Spark plug Spark plug gap Cooling system Cooling liquid Starting equipment 400/620 Supercompetition ‘99 400 LC4 620 LC4 Liquid-cooled single cylinder 4-stroke engine with balancer shaft 398 ccm 609 ccm 89 / 64 mm 101 / 76 mm 10,8 : 1 10,4 : 1 unleaded premium gasoline with a least RON 95 4 valves over rocker arm and 1 overhead camshaft, camshaft drive through single chain 249/1 IO 22° BTDC EO 60° BBDC IO 15° BTDC EO 52° BBDC IC 42° ABDC EC 4° ATDC IC 54° ABDC EC 17° ATDC Intake: 36 mm Exhaust: 30 mm Intake: 0,20 mm Exhaust: 0,20 mm Intake: 0,15 mm Exhaust: 0,15 mm 2 cylinder roller bearing needle bearing bronze bushing cast aluminium alloy 1 compression ring, 1 taper face ring, 1 oil scraper ring forced-feed lubrication through 2 Eaten-oilpumps see bellow # 1,6 liters (0,42 US gallons) straight geared spur wheels 30 : 81 teeth multi disc clutch in oil bath 5-speed claw shifted 1st 14:35 2nd 15:24 3rd 18:21 4th 20:19 5th 22:18 contactless thyristor ignition with electronic advanced system type KOKUSAN adjustment to max. 40 ° BTDC at 5000 rpm adjustment to max. 36 ° BTDC at 5000 rpm 12V 110W NGK DPR8 EA-9 0,90 mm liquid cooled, permanent rotation of cooling liquid through mechanic driven water pump 1 liter, 40% antifreeze, 60% water, at least –25°C (–13°F) decompressor automatic and hand actuated, cold and hot start knob on carburetor BASIC CARBURETOR SETTING Carburetor Carburetor setting number Main jet Needle jet Idling jet Jet needle Needle position from top Mixture.adj. screw open Throttle valve Starting jet Performance restrictor 400 SC (20 kW) 400 SC 620 SC (20 kW) 620 SC PHM 38 SD 300896 150 DR 266 45 K 51 3 rd 1,5 turn 40 45 slide stop 22 mm PHM 38 SD 4894/6 190 DR 270 (DR 272) 45 K 51 2 nd 1,5 turn 40 45 – PHM 40 SD 110996 155 DR 268 45 K 51 3 rd 1,5 turn 40 45 slide stop 26 mm PHM 40 SD 4922 195 DR 272 45 K 51 2 nd 1,5 turn 40 45 – 10-22D ASSEMBLY CLEARANCE, WEAR LIMIT Crank shaft Conrod bearing Piston forged Piston cast Piston rings end gap Valves Oil pump Bypaß valve Clutch discs Clutch springs Transmission shafts axial play..................................................0,03 - 0,12 mm run out of crank stud .................................max. 0,04 mm radial play ..................................................max. 0,05 mm axial play ...................................................max. 1,00 mm assembly clearance ...................................max. 0,12 mm assembly clearance ...................................max. 0,05 mm compression rings ......................................max. 0,60 mm oil scraper ring ...........................................max. 0,80 mm seat sealing intake......................................max. 1,50 mm seat sealing exhaust ...................................max. 2,00 mm run out of valve heads ...............................max. 0,03 mm valve guides diameter ................................max. 7,05 mm clearance outer rotor - housing..................max. 0,20 mm clearance outer rotor - inner rotor..............max. 0,20 mm minimum spring length..........................................25 mm wear limit organic .................................................2,5 mm minimum length ...........................34,5 mm (new 37 mm) axial play......................................................0,1 - 0,4 mm (0,001-0,005 in) (0,002 in) (0,002 in) (0,04 in) (0,005 in) (0,002 in) (0,023 in) (0,031 in) 0,059 in) (0,080 in) (0,001 in) (0,277 in) (0,008 in) (0,008 in) (1 in) (0,1 in) (1,36 in - new 1,45 in) (0,004 - 0,016 in) TIGHTENING TORQUES - ENGINE Hexagon nut at primary gear Collar nut flywheel Hexagon nut for inner clutch hub Kickstarter stop bolt AH bolts oil pump Hexagon bolt camshaft gear AH bolt cylinder head top sect. AH bolt cylinder head top sect. AH bolt cylinder head top sect. Cylinder head bolts Collar nuts at cylinder base Hexagon bolt chain sprocket Oil drain plug Magnetic plug Plug bypass valve Banjo bolts oil lines Banjo bolt oil lines Jet screw clutch cover Bolt plug timing-chain tensioner Counternuts valve adjusting screws Spark plug Crankshaft locking bolt Engine fastening bolt M M M M M M M M M M M M M M M M M M M M M M M M 20x1,5 12x1 LH thread 18x1,5 12x1,5 6 10 6x25 6x50/M 6x55 (12.9) 6x65/M6x70 (8.8) 10 10 10 22x1,5 12x1,5 12x1,5 8x1 10x1 8x1 12x1,5 7x0,75 12x1,25 8 8 10 API: SF, SG, SH TEMPERATURE – 10W 40 10W 50 10W 60 0°C 32°F + 15W 40 15W 50 15W 60 Loctite 243 +170 60 Loctite 648 + 80 50 Loctite 243 + 8 Loctite 243 + 35 8 20 8 50 40 Loctite 243 + 40 30 20 20 10 15 10 20 20 20 25 40 70 Nm Nm Nm Nm Nm Nm Nm Nm Nm Nm Nm Nm Nm Nm Nm Nm Nm Nm Nm Nm Nm Nm Nm Nm (125 ft.lb) (44 ft.lb) (59 ft.lb) (37 ft.lb) (6 ft.lb) (26 ft.lb) (6 ft.lb) (15 ft.lb) (6 ft.lb) (37 ft.lb) (30 ft.lb) (30 ft.lb) (22 ft.lb) (15 ft.lb) (15 ft.lb) (7 ft.lb) (11 ft.lb) (7 ft.lb) (15 ft.lb) (15 ft.lb) (15 ft.Ib) 18 ft.lb) (30 ft.lb) (51 ft.lb) # Engine oil Use only oil brands (Shell Advance Ultra 4), which meet quality requirements of API-classes SF, SG or SH (informations on bottles) or higher. Both, mineral and synthetic oils with above specifications can be used. ! POOR CAUTION ! OIL QUALITY OR MINOR QUANTITY EFFECT EARLY ENGINE-WEAR. 10-23D TECHNICAL SPECIFICATIONS - CHASSIS 400 / 620 Supercompetition ‘99 400 SC 620 SC Frame Central chrome-moly-steel frame Fork White Power – Up Side Down 43 Wheel travel front/rear Rear suspension 295 / 320 mm (11,6 / 12,6 in) Central shock absorber (WP) with PRO-LEVER linkage to rear-swingarm with needle bearing Front brake Disc brake with carbon-steel brake disc Ø 260 mm (10,2 in), brake caliper floated Rear brake Disc brake with carbon-steel brake disc Ø 220 mm (8,7 in), brake caliper floated Tyres front 90/90-21 54R Air pressure offroad 1,0 bar (14 psi) Air press. road, driver only 1,5 bar (21 psi) Tyres rear 140/80-18 70R Air pressure offroad 1,2 bar (17 psi) Air press. road, driver only 2,0 bar (28 psi) Fuel tank capacity 9 liter (2,38 US gallons) of that 2,5 liter (0,66 US gallons) reserve Final drive ratio 16:48 (14:50) 16:40 (15:50) Chain 5/8 x 1/4 " O-Ring Steering angle 62,5° Wheel base 1510 ± 10 mm (59,4 ± 0,4 in) Art.-Nr. 3.206.006 -E Seat high 940 mm (37 in) Ground clearance 375 mm (14,8 in) Dead weight without fuel 122 kg (269 lbs) STANDARD ADJUSTMENT - FORK STANDARD-ADJUSTMENT - SHOCK ABSORBER 05.18.T7.81 01.18.T7.05 Compression adjuster 10 Compression adjuster Rebound adjuster 12 Rebound adjuster Spring 4,2 N/mm Spring preload 6 mm (0,24 in) Air chamber length 130 mm (5,1 in) Capacity per fork leg Fork oil Spring 5 63 / 260 Spring preload 23 mm (0,9 in) app. 700 ccm SAE 5 NOTE FOR WHITE POWER FORKS: The damping units in the left and the right fork leg are of different design. Make sure not to mix them up in case of repair or service works. Repair manual KTM LC4 3 TIGHTENING TORQUES - CHASSIS Collar bolt front axle M 10 40 Nm (30 ft.lb) Brake caliper front M8 Loctite 243 + 25 Nm (18 ft.lb) Collar nut rear axle M 20x1,5 80 Nm (59 ft.lb) Hex. nut swing arm bolt M 14x1,5 100 Nm (74 ft.lb) Collar bolts handlebar clamps M8 20 Nm (15 ft.lb) Collar bolts handlebar support M 10 40 Nm (30 ft.lb) Clamping bolt top triple clamp M8 23 Nm (17 ft.lb) Clamping bolt bottom triple clamp M8 18 Nm (13 ft.lb) Clamping bolts fork leg axle passage M8 10 Nm (7 ft.lb) Other bolts chassis M6 10 Nm (7 ft.lb) M8 25 Nm (18 ft.lb) M 10 45 Nm (33 ft.lb) 10-24D TECHNICAL SPECIFICATIONS – ENGINE Engine Design Displacement Bore / Stroke Ratio Fuel Valve timing Camshaft Valve timing by 1 mm valve clearance Valve diameter Valve clearance cold Crankshaft bearing Conrod bearing Top end bearing Piston Piston rings Engine lubrication Engine oil Engine oil quantity Primary ratio Clutch Transmission Gear ratio Ignition system Ignition timing Generator Spark plug Spark plug gap Cooling system Cooling liquid Starting equipment 620 LC4 COMPETITION ‘99 620 LC4 COMPETITION Liquid-cooled single cylinder 4-stroke engine with balancer shaft 609 cm3 101 / 76 mm 10,4 : 1 unleaded premium gasoline with a least RON 95 4 valves over rocker arm and 1 overhead camshaft, camshaft drive through single chain 249/1 IO 15° BTDC EO 52° BBDC IC 54° ABDC EC 17° ATDC Intake: 36 mm Exhaust: 30 mm Intake: 0,15 mm Exhaust: 0,15 mm 2 cylinder roller bearing needle bearing bronze bushing cast aluminium alloy 1 compression ring, 1 taper face ring, 1 oil scraper ring forced-feed lubrication through 2 Eaten-oilpumps see bellow # 2,1 liters including frame straight geared spur wheels 30 : 81 teeth multi disc clutch in oil bath 5-speed claw shifted 1st 14:35 2nd 15:24 3rd 18:21 4th 20:19 5th 22:18 contactless thyristor ignition with electronic advanced system type SEM adjustment to max. 32 ° BTDC at 6000 rpm 12V 130W NGK DPR8 EA-9 0,90 mm liquid cooled, permanent rotation of cooling liquid through mechanic driven water pump 1 liter, 40% antifreeze, 60% water, at least –25 ° C (–13 ° F) decompressor automatic and hand actuated, cold and hot start knob on carburetor TIGHTENING TORQUES - ENGINE Hexagon nut at primary gear Collar nut flywheel Hexagon nut for inner clutch hub Kickstarter stop bolt AH bolts oil pump Hexagon bolt camshaft gear AH bolt cylinder head top sect. AH bolt cylinder head top sect. AH bolt cylinder head top sect. Cylinder head bolts Collar nuts at cylinder base Hexagon bolt chain sprocket Oil drain plug Magnetic plug Plug bypass valve Banjo bolts oil lines Banjo bolt oil lines Jet screw clutch cover Bolt plug timing-chain tensioner Counternuts valve adjusting screws Spark plug M M M M M M M M M M M M M M M M M M M M M 20x1,5 Loctite 243 +170 12x1 LH thread 60 18x1,5 Loctite 648 + 80 12x1,5 50 6 Loctite 243 + 8 10 Loctite 243 + 35 6x25 8 6x50/M 6x55 (12.9) 20 6x65/M 6x70 (8.8) 8 10 50 10 40 10 Loctite 243 + 40 22x1,5 30 12x1,5 20 12x1,5 20 8x1 10 10x1 15 8x1 10 12x1,5 20 7x0,75 20 12 20 Nm (125 ft.lb) Nm (44 ft.lb) Nm (59 ft.lb) Nm (37 ft.lb) Nm (6 ft.lb) Nm (26 ft.lb) Nm (6 ft.lb) Nm (15 ft.lb) Nm (6 ft.lb) Nm (37 ft.lb) Nm (30 ft.lb) Nm (30 ft.lb) Nm (22 ft.lb) Nm (15 ft.lb) Nm (15 ft.lb) Nm (7 ft.lb) Nm (11 ft.lb) Nm (7 ft.lb) Nm (15 ft.lb) Nm (15 ft.lb) Nm (15 ft.Ib) 10-25D ASSEMBLY CLEARANCE, WEAR LIMIT Crank shaft Conrod bearing Piston Piston ring end gap Valves Oil pump Bypaß valve Clutch discs Transmission shafts Clutch axial play..................................................0,03 - 0,12 mm (0,001-0,005 in) run out of crank stud .................................max. 0,08 mm radial play ..................................................max. 0,05 mm axial play ...................................................max. 1,00 mm assembly clearance ...................................max. 0,12 mm compression rings ......................................max. 0,60 mm oil scraper ring ...........................................max. 0,80 mm seat sealing intake......................................max. 1,50 mm seat sealing exhaust ...................................max. 2,00 mm run out of valve heads ...............................max. 0,05 mm valve guides diameter ................................max. 7,05 mm clearance outer rotor - housing..................max. 0,20 mm clearance outer rotor - inner rotor..............max. 0,20 mm minimum spring length..........................................25 mm wear limit organic .................................................2,5 mm axial play......................................................0,1 - 0,4 mm minimum clutchspring length...........34,5 mm (new 37 mm) (0,0031 in) (0,0019 in) (0,04 in) (0,005 in) (0,023 in) (0,031 in) 0,059 in) (0,079 in) (0,002 in) (0,277 in) (0,008 in) (0,008 in) (1 in) (0,1 in) (0,004 in) (1,36 in - new 1,45 in) Art.-Nr. 3.206.006 -E BASIC CARBURETOR SETTING Carburetor Carburetor setting number Main jet Needle jet Idling jet Jet needle Needle position from top Mixture.adju. screw open Throttle valve Starting jet Performance restrictor Repair manual KTM LC4 # 620 LC4 COMP. 24 kW 620 LC4 COMP. 37 kW PHM 40 SD 110996 155 DR 268 45 K 51 3 rd 1,5 turn 40 45 slide stop 26 mm PHM 40 SD 110996 155 DR 268 45 K 51 3 rd 1,5 turn 40 45 – API: SF, SG, SH TEMPERATUR – 10W 40 10W 50 10W 60 + 0°C 32°F 15W 40 15W 50 15W 60 Engine oil Use only oil brands,(Shell Advance Ultra 4) which meet quality requirements of API-classes SF, SG or SH (informations on bottles) or higher. Both, mineral and synthetic oils with above specifications can be used. ! POOR CAUTION ! OIL QUALITY OR MINOR QUANTITY EFFECT EARLY ENGINE-WEAR. 10-26D TECHNICAL SPECIFICATIONS - CHASSIS Frame Fork Wheel travel front/rear Rear suspension Front brake Rear brake Tyres front Air press. road, driver only Air press. road with passenger Tyres rear Air press. road, driver only Air press. road with passenger Fuel tank capacity Final drive ratio Chain Battery Steering angle Wheel base Seat high Ground clearance Dead weight without fuel Max. permissible front axle load Max. permissible rear axle load Max. permissible laden weight 620 LC4 COMPETITION Central chrome-moly-steel frame WP Extreme 280 / 320 mm (11,0 / 12,6 in) Central shock absorber (WP) with PRO-LEVER linkage to rear-swingarm with needle bearing Disc brake with carbon-steel brake disc , brake caliper floated brake disc Ø = 300 mm (11,8 in) Disc brake with carbon-steel brake disc Ø 220 mm (8,7 in), brake caliper floated 90/90-21 T63 1,5 bar (21 psi) 2,0 bar (28 psi) 130/80-18 T63 2,0 bar (28 psi) 2,2 bar (31 psi) 12 liter (3,2 US gallons) of that 2,5 liter (0,7 US gallons) res 16:40 O-ring 5/8 x 1/4" maintenance-free battery 12V 8Ah 62,5° 1510 ± 10 mm (59,4 ± 0,4 in) 955 mm (37,6 in) 335 mm (13,2 in) 133 kg (293 lbs) 211 kg (466 lbs) 335 kg (737 lbs) 350 kg (770 lbs) STANDARD ADJUSTMENT - FORK Compression adjuster Rebound adjuster Spring Spring preload Air chamber length Capacity per fork leg Fork oil STANDARD-ADJUSTMENT - SHOCK ABSORBER 118 S 701 918 S 757 12 12 4,4 N/mm 10 mm 160 mm app. 800 ccm SAE 5 Compression adjuster Rebound adjuster Spring Spring preload Collar nut rear axle Hex. nut swing arm bolt Clamping bolt top triple clamp Clamping bolt bottom triple clamp Clamping bolts fork leg axle passage Other bolts chassis M 10 M8 M 20x1,5 M 14x1,5 M8 M8 M8 M6 M8 M 10 3 5 66/260 23 mm NOTE FOR WP EXTREME FORKS: The damping units in the left and the right fork leg are of different design. Make sure not to mix them up in case of repair or service works. TIGHTENING TORQUES - CHASSIS Collar bolt front axle Brake caliper front 620 LC4 COMPETITION ‘99 40 Nm 25 Nm + 80 Nm 100 Nm 15 Nm 20 Nm 10 Nm 10 Nm 25 Nm 45 Nm (30 ft.lb) (19 ft.lb) Loctite 243 (59 ft.lb) (74 ft.lb) (11 ft.lb) (15 ft.lb) (7 ft.lb) (7 ft.lb) (19 ft.lb) (33 ft.lb) 10-27D TECHNICAL DATA – ENGINE 400 / 640 LC4 ‘99 Engine 400 LC4-E Design 640 LC4-E Liquid-cooled single cylinder 4-stroke engine with balancer shaft and electric starter Displacement 398 ccm 625 ccm Bore / Stroke 89 / 64 mm 101 / 78 mm Ratio 10,8 : 1 Fuel 11 : 1 unleaded premium gasoline with at least RON 95 Valve timing 4 valves over rocker arm and 1 overhead camshaft, camshaft drive through single chain Camshaft 249/1 Valve timing by 1 mm IO 22° BTDC valve clearance EO 60° BBDC IO 13° BTDC EO 53° BBDC EC 4° ATDC IC 51° ABDC EC 11° ATDC IC 47° ABDC Valve diameter Intake: 36 mm Valve clearance cold Intake: 0,20 mm Crank shaft bearing Intake: 0,15 mm Exhaust: 0,15 mm 2 cylinder roller bearing Conrod bearing needle bearing Top end bearing bronze bushing Piston forged/cast aluminium alloy Piston rings 1 compression ring, 1 taper face ring, 1 oil scraper ring Engine lubrication two Eaten-oilpumps Engine oil see bellow # Engine oil quantity appr. 2,1 liters including frame Primary ratio straight geared spur wheels 30 : 81 teeth Clutch multi disc clutch in oil bath Transmission Art.-Nr. 3.206.006 -E Exhaust: 30 mm Exhaust: 0,20 mm 5-speed claw shifted Gear ratio 1st 14:35 2nd 15:24 3rd 18:21 4th 20:19 5th 22:18 Ignition system contactless DC-CDI ignition with digital advanced system type KOKUSAN Ignition timing adjustment to max. 38° BTDC at 6000 rpm Generator 12V 200W Spark plug NGK DPR8 EA-9 Spark plug gap 0,90 mm Cooling system liquid cooled, permanent rotation of cooling liquid through mechanic driven water pump Cooling liquid 1 liter, 40% antifreeze, 60% water, at least –25 ° C (–13 ° F) Starting equipment electric starter and kickstarter Repair manual KTM LC4 # Engine oil API: SF, SG, SH TEMPERATURE – 10W 40 10W 50 10W 60 0°C 32°F + 15W 40 15W 50 15W 60 Use only oil brands (Shell Advance Ultra 4), which meet quality requirements of API-classes SF, SG or SH (informations on bottles) or higher. Both, mineral and synthetic oils with above specifications can be used. ! POOR CAUTION ! OIL QUALITY OR MINOR QUANTITY EFFECT EARLY ENGINE-WEAR. 10-28D BASIC CARBURETOR SETTING Carburetor Carburetor setting number Main jet Needle jet Idling jet Jet needle Needle position from top Mixture adj. screw open Throttle valve Starting jet Performance restrictor 400 LC4 25 kW 400 LC4 31 kW 640 LC4 25 kW 640 LC4 37 kW PHM 38 ND 100197 130 AR 264 50 K 23 2 nd 1,5 turn 50/1 45 (50, 55) slide stop 51 mm PHM 38 ND 100197 130 AR 264 50 K 23 2 nd 1,5 turn 50/1 45 (50, 55) – BST40-225 080298 142,5 689 X-6 45 6G5 3 rd – – – slide stop 17 mm BST40-225 090298 142,5 689 X-6 45 6G5 3 rd – – – – TIGHTENING TORQUES - ENGINE Hexagon nut at primary gear M 20x1,5 Hexagon nut flywheel M 16x1,25 LH thread Hexagon nut for inner clutch hub M 18x1,5 Loctite 243 + 170 Nm (125 ft.lb) 150 Nm (110 ft.lb) 80 Nm (59 ft.lb) Kickstarter stop bolt M 12x1,5 Allen head bolts oil pump M6 50 Nm (37 ft.lb) Hexagon bolt camshaft gear M 10 Loctite 243 + 35 Nm (26 ft.lb) Allen head bolts outer race M 6x12/M 6x12,5 Loctite 648 + 18 Nm (13 ft.lb) Allen head bolt cylinder head top sect. M 6x50/M 6x55 (12.9) Allen head bolt cylinder head top sect. M 6x25/M 6x65/M 6x70 (8.8) Cylinder head bolts M 10 50 Nm (37 ft.lb) Collar nuts at cylinder base M 10 40 Nm (30 ft.lb) Hexagon bolt chain sprocket M 10 Loctite 243 + 40 Nm (30 ft.lb) Oil drain plug M 22x1,5 Magnetic plug M 12x1,5 20 Nm (15 ft.lb) Plug bypass valve M 12x1,5 20 Nm (15 ft.lb) Crankshaft locating bolt M8 25 Nm (18 ft.lb) Hollow bolts oil lines M 8x1 10 Nm (7 ft.lb) Hollow bolts oil lines M 10x1 15 Nm (11 ft.lb) Jet screw clutch cover M8 Loctite 243 + 8 Nm (6 ft.lb) 20 Nm (15 ft.lb) 8 Nm (6 ft.lb) 30 Nm (22 ft.lb) 10 Nm (7 ft.lb) Bolt plug timing-chain tensioner M 12x1,5 20 Nm (15 ft.lb) Counternuts valve adjusting screws M 7x0,75 20 Nm (15 ft.lb) Engine fastening bolt M8 40 Nm (30 ft.lb) M 10 70 Nm (52 ft.lb) ASSEMBLY CLEARANCE, WEAR LIMIT Crank shaft axial play ....................0,03 - 0,12 mm (0,0012 - 0,0047 in) run out of crank stud ..................max. 0,04 mm (0,0031 in) Conrod bearing radial play .....................................max. 0,05 mm (0,002 in) axial play .......................................max. 1,00 mm (0,043 in) Cylinder bore diameter..........................max. 101,04 mm (3,9779 in) Piston assembly clearance ......................max. 0,12 mm (0,0047 in) Piston ring end gap compression rings........................max. 0,80 mm (0,0315 in) oil scraper ring...............................max. 1,0 mm (0,0394 in) Valves seat sealing intake .......................max. 1,50 mm (0,0591 in) seat sealing exhaust ....................max. 2,00 mm (0,0788 in) run out of valve heads ................max. 0,05 mm (0,0019 in) valve guides diameter..................max. 7,05 mm (0,2778 in) Oil pump clearance outer rotor - housing ......max. 0,20 mm (0,0079 in) Bypaß valve minimum spring length .............................25 mm (0,985 in) Clutch clutchspring length...min. 34,5 mm (1,36 in), new 37 mm (1,458 in) Camshaft diameter of bearing bolt.............min. 19,97 mm (0,7868 in) (needle bearing) Transmission shafts axial play........................0,1 – 0,4 mm (0,0039 – 0,0158 in) clearance outer rotor - inner rotor .....max. 0,20 mm (0,0079 in) wear limit organic............................min. 2,5 mm (0,0985 in) 10-29D TECHNICAL SPECIFICATIONS - CHASSIS 400 LC4 / 640 LC4 (R) / SUPERMOTO ‘99 400 LC4 / 640 LC4 640 Supermoto Frame Central chrome-moly-steel frame Fork WP Extreme Wheel travel front/rear 280 / 320 mm (11 / 12.6 in) Rear suspension Disc brake with carbon-steel brake disc 300 mm (11.8 in), brake caliper floated Disc brake with carbon-steel brake disc 220 mm (8.7 in), brake caliper floated Rear brake Tyres front 90/90-21 120/70-17 90/90-21 Air press. road, driver only 1.5 bar (22 psi) 2.0 bar (29 psi 1.5 bar (22 psi) Air press. road with passenger 2.0 bar (29 psi) 2.2 bar (31 psi) 2.0 bar (29 psi) 140/80-18 160/60-17 140/80-18 Air press. road, driver only 2.0 bar (29 psi) 2.2 bar (31 psi) 2.0 bar (29 psi) Air press. road with passenger 2.2 bar (31 psi) 2.4 bar (34 psi) 2.2 bar (31 psi) Tyres rear Fuel tank capacity Final drive ratio 12 or 18 liter (3.2 or 4.8 US gallons), 2.5 liter (0,6 US gallons) reserve 400 LC4 - 15:45 640 LC4 - 16:42 17:40 16:42 Chain O – Ring 5/8 x 1/4" Battery maintenance-free battery 12V 8Ah Steering angle 62,5 ° 63° Wheel base 62.5° 1510 ± 10 mm (59.4 ± 0.4 in) Seat high 955 mm (37.6 in) 935 mm (36.8 in) Ground clearance 375 mm (14.8 in) 355 mm (13.9 in) Dead weight without fuel Art.-Nr. 3.206.006 -E 250 / 290 mm (10 / 11.4 in) Central shock absorber (WP) with PRO-LEVER linkage to rear- swing-arm with needle bearing Front brake 136kg (300 lbs) 137 kg (302 Ibs) Max. permissible front axle load 211 kg (465 lbs) Max. permissible rear axle load 335 kg (740 lbs) Max. permissible loaden weight 350 kg (773 lbs) STANDARD ADJUSTMENT - FORK 918S776 12 12 Compression adjuster 12 12 Rebound adjuster 4,4 N/mm 4,4 N/mm Rebound adjuster Spring Spring preload 10 mm (0,4 in) 15 mm (0,6 in) Air chamber length 160 mm (6,3 in) 160 mm (6,3 in) app. 800 ccm app. 800 ccm SAE 5 SAE 5 Capacity per fork leg Fork oil Spring Spring preload TIGHTENING TORQUES - CHASSIS Collar bolt front axle M 10 135 kg (298 Ibs) STANDARD-ADJUSTMENT - SHOCK ABSORBER 918S757 Compression adjuster Repair manual KTM LC4 400 LC4 R / 640 LC4 R 40 Nm (30 ft.lb) Loctite 243 + 25 Nm (20 ft.lb) Brake caliper front M8 Collar nut rear axle M 20x1,5 80 Nm (60 ft.lb) Hexagon nut swingarm bolt M 14x1,5 100 Nm (74 ft.lb) Clamping bolt upper triple clamp M8 15 Nm (11 ft.lb) Clamping bolt lower triple clamp M8 20 Nm (15 ft.lb) Clamping bolts fork stubs M8 10 Nm (7 ft.lb) Other bolts chassis M6 10 Nm (7 ft.lb) M8 25 Nm (20 ft.lb) M 10 45 Nm (33 ft.lb) 118S701 118Q784 3 3 5 4 66/260 63/260 23 mm (0,9 in) 23 mm (0,9 in) 10-30D TECHNICAL DATA – ENGINE 640 LC4-E ADVENTURE R ‘99 Engine 640 LC4-E Design Liquid-cooled single cylinder 4-stroke engine with balancer shaft and electric starter Displacement 625 ccm Bore / Stroke 101 / 78 mm Ratio 11,0 : 1 Fuel unleaded premium gasoline with a least RON 95 Valve timing 4 valves over rocker arm and 1 overhead camshaft, camshaft drive through single chain Camshaft 249° (249/1) Valve timing by 1 mm IO 13° BTDC EO 53° BBDC valve clearance IC 51° ABDC EC 11° ATDC Valve diameter Intake: 36 mm Valve clearance cold 0,15 mm Crank shaft bearing Exhaust: 30 mm Exhaust: 0,15 mm 2 cylinder roller bearing Conrod bearing needle bearing Top end bearing bronze bushing Piston cast aluminium alloy Piston rings 1 compression ring, 1 taper face ring, 1 oil scraper ring Engine lubrication two Eaten-oilpumps Engine oil see below # Engine oil quantity appr. 2,1 liters including frame Primary ratio straight geared spur wheels 30 : 81 teeth Clutch multi disc clutch in oil bath Transmission 5-speed claw shifted Gear ratio 1st 14:35 2nd 15:24 3rd 18:21 4th 20:19 5th 22:18 Ignition system contactless DC-CDI ignition with digital advanced system type KOKUSAN Ignition timing adjustment to max. 38° BTDC at 6000 rpm Generator 12V 200W Spark plug NGK DPR8 EA-9 Spark plug gap 0,90 mm Cooling system liquid cooled, permanent rotation of cooling liquid through mechanic driven water pump Cooling liquid 1 liter, 40% antifreeze, 60% water, at least –25 ° C (–13 ° F) Starting equipment electric starter and kickstarter BASIC CARBURETOR SETTING Carburetor Carburetor setting number Main jet Needle jet Idling jet Jet needle Needle position from top Mixt. adj. screw open Throttle valve Starting jet Permormance restrictor 640 ADVENTURE 640 ADVENTURE 25 kW 36 kW BST40-225 080298 142,5 689 X-6 45 6G5 3 rd – – – slide stop 17 mm BST40-225 090298 142,5 689 X-6 45 6G5 3 rd – – – – 10-31D TIGHTENING TORQUES - ENGINE Hexagon nut at primary gear M 20x1,5 Hexagon nut flywheel M 16x1,25 LH thread Loctite 243 + 170 Nm (125 ft.lb) Hexagon nut for inner clutch hub M 18x1,5 150 Nm (110 ft.lb) 80 Nm (59 ft.lb) Kickstarter stop bolt M 12x1,5 Allen head bolts oil pump M6 50 Nm (37 ft.lb) Hexagon bolt camshaft gear M 10 Loctite 243 + 35 Nm (26 ft.lb) Allen head bolts outer race M 6x12/M 6x12,5 Loctite 648 + 18 Nm (13 ft.lb) Allen head bolt cylinder head top sect. M 6x50/M 6x55 (12.9) Allen head bolt cylinder head top sect. M 6x25/M 6x65/M 6x70 (8.8) Cylinder head bolts M 10 50 Nm (37 ft.lb) Collar nuts at cylinder base M 10 40 Nm (30 ft.lb) Hexagon bolt chain sprocket M 10 Loctite 243 + 40 Nm (30 ft.lb) Oil drain plug M 22x1,5 Magnetic plug M 12x1,5 20 Nm (15 ft.lb) Plug bypass valve M 12x1,5 20 Nm (15 ft.lb) Crankshaft locating bolt M8 25 Nm (18 ft.lb) Hollow bolts oil lines M 8x1 10 Nm (7 ft.lb) Hollow bolts oil lines M 10x1 15 Nm (11 ft.lb) Jet screw clutch cover M8 Loctite 243 + 8 Nm (6 ft.lb) 20 Nm (15 ft.lb) 8 Nm (6 ft.lb) 30 Nm (22 ft.lb) 10 Nm (7 ft.lb) Bolt plug timing-chain tensioner M 12x1,5 20 Nm (15 ft.lb) Counternuts valve adjusting screws M 7x0,75 20 Nm (15 ft.lb) Engine fastening bolt M8 40 Nm (30 ft.lb) M 10 70 Nm (52 ft.lb) Art.-Nr. 3.206.006 -E ASSEMBLY CLEARANCE, WEAR LIMIT Crank shaft axial play ....................0,03 - 0,12 mm (0,0012 - 0,0047 in) run out of crank stud ..................max. 0,08 mm (0,0031 in) Conrod bearing radial play .....................................max. 0,05 mm (0,002 in) axial play .......................................max. 1,10 mm (0,043 in) Cylinder bore diameter..........................max. 101,04 mm (3,9779 in) Piston assembly clearance ......................max. 0,12 mm (0,0047 in) Piston ring end gap compression rings........................max. 0,80 mm (0,0315 in) oil scraper ring...............................max. 1,0 mm (0,0394 in) Valves seat sealing intake .......................max. 1,50 mm (0,0591 in) seat sealing exhaust ....................max. 2,00 mm (0,0788 in) run out of valve heads ................max. 0,05 mm (0,0019 in) valve guides diameter..................max. 7,05 mm (0,2778 in) Oil pump clearance outer rotor - housing ......max. 0,20 mm (0,0079 in) Bypaß valve minimum spring length .............................25 mm (0,985 in) Clutch clutchspring length...min. 34,5 mm (1,36 in), new 37 mm (1,458 in) Camshaft diameter of bearing bolt.............min. 19,97 mm (0,7868 in) (needle bearing) Transmission shafts axial play........................0,1 – 0,4 mm (0,0039 – 0,0158 in) clearance outer rotor - inner rotor .....max. 0,20 mm (0,0079 in) Repair manual KTM LC4 Wear limit organic ...........................min. 2,5 mm (0,0985 in) # Engine oil API: SF, SG, SH TEMPERATURE – 10W 40 10W 50 10W 60 0°C 32°F + 15W 40 15W 50 15W 60 Use only oil brands, which meet quality requirements of API-classes SF, SG or SH (informations on bottles) or higher. Both, mineral and synthetic oils with above specifications can be used. ! POOR CAUTION ! OIL QUALITY OR MINOR QUANTITY EFFECT EARLY ENGINE-WEAR. 10-32D TECHNICAL SPECIFICATIONS - CHASSIS 640 ADVENTURE R ‘99 640 ADVENTURE R Frame Central chrome-moly-steel frame Fork WP-Extreme Ø 50 mm Wheel travel front/rear Rear suspension 300 / 320 mm (11,8 / 12,6 in) Central shock absorber WP IBS with PRO-LEVER linkage to rear- swing-arm with needle bearing Front brake Disc brake with carbon-steel brake disc 300 mm (11,8 in), brake caliper floated Rear brake Disc brake with carbon-steel brake disc 220 mm (8,7 in), brake caliper floated Tyres front 90/90 - 21 54S Enduro 3 Air press. road, driver only 1,5 bar (22 psi) Air press. road with passenger 2,0 bar (29 psi) Tyres rear 140/80 - 18 70R Enduro 3 Air press. road, driver only 2,0 bar (29 psi) Air press. road with passenger 2,2 bar (31 psi) Fuel tank capacity 28 liter (7,4 US gallons), Final drive ratio 3,8 liter (1 US gallons) reserve 16:40 t Chain O – Ring 5/8 x 1/4" Battery maintenance-free battery 12V 8Ah Steering angle 62,5 ° Wheel base 1510 ± 10 mm (59,4 ± 0,4 in) Seat high 940 mm (37 in) Ground clearance 320 mm (12,6 in) Dead weight without fuel 154 kg (340 lbs) Max. permissible front axle load 150 kg (331 lbs) Max. permissible rear axle load 230 kg (507 lbs) Max. permissible loaden weight 380 kg (839 lbs) STANDARD ADJUSTMENT - FORK 09.18.S7.55 Compression adjuster 14 Rebound adjuster 12 Spring 4,4 N/mm Spring preload 10 mm (0,4 in) Air chamber length 155 mm (5,9 in) Capacity per fork leg app. 800 ccm Fork oil SAE 5 STANDARD-ADJUSTMENT - SHOCK ABSORBER 01.18.R7.97 Compression adjuster 3 Rebound adjuster 5 Spring 70/260 Spring preload 23 mm (0,9 in) TORQUES Collar bolt front axle M 10 Brake caliper front M8 40 Nm (30 ft.lb) Loctite 243 + 25 Nm (18 ft.lb) Collar nut rear axle M 20x1,5 80 Nm (59 ft.lb) Hexagon nut swingarm bolt M 14x1,5 100 Nm (74 ft.lb) Clamping bolt upper triple clamp M8 15 Nm (11 ft.lb) Clamping bolt lower triple clamp M8 20 Nm (15 ft.lb) Clamping bolts fork stubs M8 10 Nm (7 ft.lb) Other bolts chassis M6 10 Nm (7 ft.lb) M8 25 Nm (19 ft.lb) M 10 45 Nm (33 ft.lb) 10-33D TECHNICAL DATA – ENGINE Art.-Nr. 3.206.006 -E Type Design Displacement Bore / Stroke Ratio Fuel Valve timing Camshaft Valve timing by 1 mm valve clearence Valve diameter Valve clearence cold Crank shaft bearing Connecting rod bearing Top end bearing Piston Piston rings Engine lubrication Quantity of engine oil Engine oil Primary ratio Clutch Transmission Gear ratio KTM 640 DUKE ‘99 640 LC4-E Liquid-cooled single cylinder 4-stroke engine with balancer shaft and electric starter 625 ccm 101 / 78 mm 11,0 : 1 unleaded premium gasoline with a least RON 95 4 valves over rocker arm and 1 overhead camshaft, camshaft drive through single chain 249° (249/1) IO 13° BTDC EO 53° BBDC IC 53° ABDC EC 11° ATDC Intake: 36 mm Exhaust: 30 mm Intake: 0.15 mm Exhaust: 0.15 mm 2 cylinder roller bearing needle bearing bronze bushing cast aluminium alloy 1 compression ring, 1 taper face ring, 1 oil scraper ring 2 Eaton-Oilpumps see below # 2.1 liters including frame straight geared spur wheels 30 : 81 teeth multi disc clutch in oil bath 5-speed claw shifted 1st 14:35 2nd 15:24 3rd 18:21 4th 20:19 5th 22:18 contactless DC- CDI ignition with digital advanced system type KOKUSAN adjustment to max. 38° BTDC at 6000 rpm 12V 200W NGK DPR8 EA-9 0.90 mm liquid cooled, permanent rotation of cooling liquid through mechanic driven water pump 1 liter, 40% antifreeze, 60% water, at least –25° C (–13° F) electric starter, kick starter Ignition system Ignition timing Generator Spark plug Spark plug gap Cooling system Cooling liquid Starting equipment BASIC CARBURETOR SETTING # API: SF, SG, SH Repair manual KTM LC4 640 DUKE 40 kW Carburetor Carburetor setting number Main jet Needle jet Idling jet Jet needle Needle position from top Mixture.adju. screw open BST40-225 100299 145 689 X-6 45 6G5 3 rd 2,25 turn TEMPERATURE – 10W 40 10W 50 10W 60 + 0°C 32°F 15W 40 15W 50 15W 60 Engine oil Use only oil brands (Shell Advance Ultra 4), which meet quality requirements of API-classes SF, SG or SH (informations on bottles) or higher. Both, mineral and synthetic oils with above specifications can be used. ! POOR CAUTION ! OIL QUALITY OR MINOR QUANTITY EFFECT EARLY ENGINE-WEAR. 10-34D TIGHTENING TORQUES - ENGINE Hexagon nut at primary gear M 20x1,5 Hexagon nut flywheel M 16x1,25 LH thread Hexagon nut for inner clutch hub M 18x1,5 Loctite 243 + 170 Nm (125 ft.lb) 150 Nm (110 ft.lb) Loctite 243 + 80 Nm (59 ft.lb) Kickstarter stop bolt M 12x1,5 Allen head bolts oil pump M6 50 Nm (37 ft.lb) Hexagon bolt camshaft gear M 10 Loctite 243 + 35 Nm (26 ft.lb) Allen head bolts outer race M 6x12/M 6x12,5 Loctite 648 + 18 Nm (13 ft.lb) Allen head bolt cylinder head top sect. M 6x50/M 6x55 (12.9) Allen head bolt cylinder head top sect. M 6x25/M 6x65/M 6x70 (8.8) Cylinder head bolts M 10 50 Nm (37 ft.lb) Collar nuts at cylinder base M 10 40 Nm (30 ft.lb) Hexagon bolt chain sprocket M 10 Loctite 243 + 40 Nm (30 ft.lb) Oil drain plug M 22x1,5 Magnetic plug M 12x1,5 20 Nm (15 ft.lb) Plug bypass valve M 12x1,5 20 Nm (15 ft.lb) Crankshaft locating bolt M8 25 Nm (18 ft.lb) Hollow bolts oil lines M 8x1 10 Nm (7 ft.lb) Hollow bolts oil lines M 10x1 15 Nm (11 ft.lb) Jet screw clutch cover M8 Loctite 243 + 8 Nm (6 ft.lb) 20 Nm (15 ft.lb) 8 Nm (6 ft.lb) 30 Nm (22 ft.lb) 10 Nm (7 ft.lb) Bolt plug timing-chain tensioner M 12x1,5 20 Nm (15 ft.lb) Counternuts valve adjusting screws M 7x0,75 20 Nm (15 ft.lb) Engine fastening bolt M8 40 Nm (30 ft.lb) M 10 70 Nm (52 ft.lb) ASSEMBLY CLEARANCE, WEAR LIMIT Crankshaft axial play ....................0,03 - 0,12 mm (0,0012 - 0,0047 in) run out of crank stud ..................max. 0,08 mm (0,0031 in) Conrod bearing radial play .....................................max. 0,05 mm (0,002 in) axial play .......................................max. 1,10 mm (0,043 in) Cylinder bore diameter..........................max. 101,04 mm (3,9779 in) Piston assembly clearance ......................max. 0,12 mm (0,0047 in) Piston ring end gap compression rings........................max. 0,80 mm (0,0315 in) oil scraper ring...............................max. 1,0 mm (0,0394 in) Valves seat sealing intake .......................max. 1,50 mm (0,0591 in) seat sealing exhaust ....................max. 2,00 mm (0,0788 in) run out of valve heads ................max. 0,05 mm (0,0019 in) valve guides diameter..................max. 7,05 mm (0,2778 in) Oil pump clearance outer rotor - housing ......max. 0,20 mm (0,0079 in) Bypaß valve minimum spring length .............................25 mm (0,985 in) Clutch clutchspring length...min. 34,5 mm (1,36 in), new 37 mm (1,458 in) Camshaft diameter of bearing bolt.............min. 19,97 mm (0,7868 in) (needle bearing) Transmission shafts axial play........................0,1 – 0,4 mm (0,0039 – 0,0158 in) clearance outer rotor - inner rotor .....max. 0,20 mm (0,0079 in) Wear limit organic ...........................min. 2,5 mm (0,0985 in) 10-35D TECHNICAL SPECIFICATIONS - CHASSIS Frame Fork Rear suspension Shock absorber Repair manual KTM LC4 Art.-Nr. 3.206.006 -E Front brake Rear brake Tyres Air pressure rider only Air pressure with passenger Fuel tank capacity Final drive ratio Chain Lamps Battery Steering angle Wheel base Seat high Ground clearance Dead weight without fuel Max. permissible front axle load Max. permissible rear axle load Max. permissible laden weight KTM 640 DUKE ‘99 Central chrome-moly-steel frame type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP - USD 43 Top adjuster 518T780 wheel travel . . . . . . . . . . . . . . . . . . . . . . . . . . 140 mm (5,5 in) standard adjustment compression. . . . . . . . . . . driver only = 14, with passenger = 14 standard adjustment rebound. . . . . . . . . . . . . . driver only = 14, with passenger = 14 fork leg projection upper fork bridge . . . . . . . . 3 mm (0.12 in) oil capacity per fork leg . . . . . . . . . . . . . . . . . . appr. 750 ccm (45 cubic in) / SAE 5 air chamber lenght . . . . . . . . . . . . . . . . . . . . . 100 mm (4 in) WP central shock absorber with PRO-LEVER linkage to rear- swing-arm with needle bearing type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP central shock absorber BAVP 118Q785 rear wheel travel . . . . . . . . . . . . . . . . . . . . . . . 170 mm (6.7 in) standard adjustment compression. . . . . . . . . . . driver only = 3, with passenger = 5 standard adjustment rebound. . . . . . . . . . . . . . driver only = 5, with passenger = 3 spring preload . . . . . . . . . . . . . . . . . . . . . . . . . driver only = 23 mm (0.9 in),with passenger = 28 mm (1.1 in) spring type . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 - 260 Disc brake with carbon-steel brake disc Ø 320 mm (12,6 in) and 4-piston brake caliper Disc brake with carbon-steel brake disc Ø 220 mm (8,7 in) and single-piston brake caliper floated front: 120/70 R 17 58H rear: 160/60 R 17 69H 2.0 bar (29 psi) 2.2 bar (32 psi) 2.2 bar (32 psi) 2.4 bar (35 psi) 12 liter (3,2 US gallons), out of this 2,5 liter (0,6 US gallons) reserve 17 : 38 o-ring 5/8 x 1/4" low beam . . . . . . . . . . . . . . . . . . . . . . . . . . . . HB3 12V 65W (socket P20d) high beam . . . . . . . . . . . . . . . . . . . . . . . . . . . HB3 12V 65W (socket P20d) parking light . . . . . . . . . . . . . . . . . . . . . . . . . . 12V 5W (socket W2,1x9,5d) speedometer, tachometer light . . . . . . . . . . . . . 12V 1,2W (socket W2x4,6d) indicator lamp . . . . . . . . . . . . . . . . . . . . . . . . . 12V 1,2W (socket W2x4,6d) stop and taillight . . . . . . . . . . . . . . . . . . . . . . . 12V 21/5W (socket BaY15d) flasher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12V 10W (socket Ba15s) maintenance-free battery 12V 8Ah 64,2° 1460 ± 15 mm (57.5 ± 0.6 in) 860 mm (33.9 in) 250 mm (9.9 in) 145 kg (3 lbs) 150 kg (2 lbs) 200 kg (4 lbs) 350 kg (773 lbs) TIGHTENING TORQUES - CHASSIS Front axle Rear axle Hex. nut swing arm bolt Clamping bolt upper fork bridge Clamping bolt lower fork bridge Clamping bolts fork stubs AH bolts front brake caliper AH bolt rear brake caliper support Collar nuts chain tension eccentrics Collar nut conrod pro lever system Bolts handlebar clamps Bolt adjusting ring spring preload shock absorber Other bolts chassis M 17 M20x1.5 M14x1.5 M8 M8 M8 M10x1,25 M10 M10 M12x1,75 M8 M6 M6 M8 M10 40 80 100 15 15 15 Loctite 243 + 40 40 40 60 25 8 10 25 45 Nm Nm Nm Nm Nm Nm Nm Nm Nm Nm Nm Nm Nm Nm Nm (30 ft.lb) (59 ft.lb) (74 ft.lb) (11 ft.lb) (11 ft.lb) (11 ft.lb) (30 ft.lb) (30 ft.lb) (30 ft.lb) (44 ft.lb) (15 lb.ft) (6 ft.lb9 (7 ft.lb) (22 ft.lb) (33 ft.lb) 10-36D TECHNICAL SPECIFICATIONS – ENGINE Engine Design Displacement Bore / Stroke Ratio Fuel Valve timing Camshaft Valve timing by 1 mm valve clearence Valve diameter Valve clearence cold Crank shaft bearing Conrod bearing Top end bearing Piston Piston rings Engine lubrication Engine oil Engine oil quantity Primary ratio Clutch Transmission Gear ratio Ignition system Ignition timing Generator Spark plug Spark plug gap Cooling system Cooling liquid Starting equipment 400/620 SC, Supermoto 2000 400 LC4 620 LC4 Liquid-cooled single cylinder 4-stroke engine with balancer shaft 398 ccm 609 ccm 89 / 64 mm 101 / 76 mm 10,8 : 1 10,4 : 1 unleaded premium gasoline with a least RON 95 4 valves over rocker arm and 1 overhead camshaft, camshaft drive through single chain 249/1 IO 22° BTDC EO 60° BBDC IO 15° BTDC EO 52° BBDC IC 42° ABDC EC 4° ATDC IC 54° ABDC EC 17° ATDC Intake: 36 mm Exhaust: 30 mm Intake: 0,20 mm Exhaust: 0,20 mm Intake: 0,15 mm Exhaust: 0,15 mm 2 cylinder roller bearing needle bearing bronze bushing cast aluminium alloy 1 compression ring, 1 taper face ring, 1 oil scraper ring forced-feed lubrication through 2 Eaten-oilpumps with oil sump see below # 1,6 liters (0,42 US gallons) straight geared spur wheels 30 : 81 teeth multi disc clutch in oil bath 5-speed claw shifted 1st 14:35 2nd 15:24 3rd 18:21 4th 20:19 5th 22:18 contactless thyristor ignition with electronic advanced system type KOKUSAN 4K-3 adjustment to max. 40 ° BTDC at 5000 rpm adjustment to max. 36 ° BTDC at 5000 rpm 12V 110W NGK DPR8 EA-9 0,90 mm liquid cooled, permanent rotation of cooling liquid through mechanic driven water pump 1 liter, 40% antifreeze, 60% water, at least –25°C (–13°F) decompressor automatic and hand actuated, cold and hot start knob on carburetor BASIC CARBURETOR SETTING Carburetor Carburetor setting number Main jet Needle jet Idling jet Jet needle Needle position from top Mixture.adju. screw open Throttle valve Starting jet Performance restrictor 400 SC (20 kW) 400 SC 620 SC (20 kW) 620 SC PHM 38 SD 300896 150 DR 266 45 K 51 3 rd 1,5 turn 40 45 slide stop 22 mm PHM 38 SD 4894/6 190 DR 270 (DR 272) 45 K 51 2 nd 1,5 turn 40 45 – PHM 40 SD 110996 155 DR 268 45 K 51 3 rd 1,5 turn 40 45 slide stop 26 mm PHM 40 SD 4922 195 DR 272 45 K 51 2 nd 1,5 turn 40 45 – 10-37D ASSEMBLY CLEARANCE, WEAR LIMIT Crank shaft axial play..................................................0.03 - 0.12 mm run out of crank stud .................................max. 0.04 mm radial play ..................................................max. 0.05 mm axial play ...................................................max. 1.00 mm assembly clearance ...................................max. 0.12 mm assembly clearance ...................................max. 0.05 mm compression rings ......................................max. 0.60 mm oil scraper ring ...........................................max. 0.80 mm seat sealing intake......................................max. 1.50 mm seat sealing exhaust ...................................max. 2.00 mm run out of valve heads ...............................max. 0.03 mm valve guides diameter ................................max. 7.05 mm clearance outer rotor - housing..................max. 0.20 mm clearance outer rotor - inner rotor..............max. 0.20 mm minimum spring length..........................................25 mm wear limit organic .................................................2.5 mm minimum length ...........................34.5 mm (new 37 mm) axial play......................................................0.1 - 0.4 mm Conrod bearing Piston forged Piston cast Piston rings end gap Valves Oil pump Bypaß valve Clutch discs Clutch springs Transmission shafts # Art.-Nr. 3.206.006 -E API: SG, SH TEMPERATURE – 10W 40 10W 50 + 0°C 32°F 15W 40 15W 50 Engine oil Use only synthetic oil (Shell Advance Ultra 4), which meet quality requirements of API-classes SG or SH (informations on bottles) or higher. ! Repair manual KTM LC4 POOR CAUTION ! OIL QUALITY OR MINOR QUANTITY EFFECT EARLY ENGINE-WEAR. (0.001-0.005 in) (0.002 in) (0.002 in) (0.04 in) (0.005 in) (0.002 in) (0.023 in) (0.031 in) 0.059 in) (0.080 in) (0.001 in) (0.277 in) (0.008 in) (0.008 in) (1 in) (0.1 in) (1.36 in - new 1.45 in) (0.004 - 0.016 in) 10-38D TECHNICAL SPECIFICATIONS - CHASSIS 400 / 620 SC, Supermoto 400/620 SC 620 Supermoto Frame Central chrome-moly-steel frame Fork White Power – Up Side Down 43 Wheel travel front/rear Rear suspension Front brake Rear brake Tyres front 295 / 320 mm (11.6 / 12.6 in) Central shock absorber (WP) with PRO-LEVER linkage to rear-swingarm with needle bearing Disc brake with carbon-steel brake disc Disc brake with carbon-steel brake disc Ø 260 mm (10.2 in), brake caliper floated Ø 320 mm (12.6 in), brake caliper floated Disc brake with carbon-steel brake disc Ø 220 mm (8.7 in), brake caliper floated 90/90-21 Pirelli MT 21 120/70-17 Pirelli MT 60 Air pressure offroad 1.0 bar (14 psi) – Air press. road, driver only 1.5 bar (21 psi) 2.0 bar (28 psi) 140/80-18 Pirelli MT 21 160/60-17 Pirelli MT 60 Air pressure offroad 1.2 bar (17 psi) – Air press. road, driver only 2.0 bar (28 psi) 2.2 bar (31 psi) Tyres rear Fuel tank capacity Final drive ratio 9 liter (2.38 US gallons) of that 2.5 liter (0.66 US gallons) reserve 400: 16:48 620: 16:40 Chain 17:38 5/8 x 1/4 " O-Ring Steering angle 62.5° Wheel base 1510 ± 10 mm (59.4 ± 0.4 in) Seat height 940 mm (37 in) 920 mm (36 in) Ground clearance 375 mm (14.8 in) 355 mm (14 in) Dead weight without fuel 122 kg (269 lbs) 123 kg (271 lbs) STANDARD ADJUSTMENT - FORK STANDARD ADJUSTMENT - SHOCK ABSORBER 05.18.U7.82 01.18.T7.05 Compression adjuster 14 Compression adjuster Rebound adjuster 14 Rebound adjuster Spring Spring preload Air chamber length Capacity per fork leg Fork oil 2000 4.2 N/mm 7 mm (0.28 in) 120 mm (4.72 in) app. 420 ccm SAE 5 Spring Spring preload 3 5 63 / 260 23 mm (0.9 in) 10-39D Art.-Nr. 3.206.006 -E TECHNICAL DATA – ENGINE 400/640 LC4-E, 640 ADVENTURE, DUKE 2000 Type Design Displacement Bore / Stroke Ratio Fuel Valve timing Camshaft Valve timing by 1 mm valve clearence Valve diameter Valve clearence cold Crank shaft bearing Connecting rod bearing Top end bearing Piston Piston rings Engine lubrication Quantity of engine oil Engine oil Primary ratio Clutch Transmission Ignition system Ignition timing Generator Spark plug Spark plug gap Cooling system Cooling liquid Starting equipment 400 LC4-E 640 LC4-E Liquid-cooled single cylinder 4-stroke engine with balancer shaft and electric starter 398 ccm 624,6 ccm 89 / 64 mm 101 / 78 mm 10,8 : 1 11,0 : 1 unleaded premium gasoline with a least RON 95 4 valves over rocker arm and 1 overhead camshaft, camshaft drive through single chain (249/1) IO 22° BTDC EO 60° BBDC IO 13° BTDC EO 53° BBDC IC 42° ABDC EC 4° ATDC IC 51° ABDC EC 11° ATDC Intake: 36 mm Exhaust: 30 mm Intake: 0.20 mm Exhaust: 0.20 mm Intake: 0.15 mm Exhaust: 0.15 mm 2 cylinder roller bearing needle bearing bronze bushing forged/cast aluminium alloy 1 compression ring, 1 taper face ring, 1 oil scraper ring 2 Eaton-Oilpumps see table 2.1 liters including frame straight geared spur wheels 30 : 81 teeth multi disc clutch in oil bath 5-speed claw shifted contactless DC- CDI ignition with digital advanced system type KOKUSAN adjustment to max. 38° BTDC at 6000 rpm 12V 200W DPR8 EA9 0.9 mm liquid cooled, permanent rotation of cooling liquid through mechanic driven water pump 1 liter, 40% antifreeze, 60% water, at least –25° C (–13° F) electric starter, kick starter Engine oil API: SG, SH TEMPERATURE Repair manual KTM LC4 – 0°C 32°F 10W 40 10W 50 Use only synthetic oils, which meet quality requirements of API-classes SG or SH (informations on bottles) or higher. + ! POOR 15W 40 15W 50 GEAR RATIOS Primary ratio 30:81 Transmission 1st gear 2nd gear 3rd gear 4th gear 5th gear 14:35 15:24 18:21 20:19 22:18 CAUTION ! OIL QUALITY OR MINOR QUANTITY EFFECT EARLY ENGINE-WEAR. Original final drive ratio Available chain drive sprockets Available final drive sprockets 15:45 16:42 17:38 17:42 15 t 16 t for chain 17 t 5/8 x 1/4" 38 40 42 45 48 t t for chain t 5/8 x 1/4" t t 10-40D ASSEMBLY CLEARANCE, WEAR LIMIT Crank shaft axial play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.03 - 0.12 mm run out of crank stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .max. 0.08 mm radial play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .max. 0.05 mm axial play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .max. 1.10 mm bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .max. 89.04 mm bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .max. 101.04 mm assembly clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .max. 0.12 mm assembly clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .max. 0.05 mm compression rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .max. 0.80 mm oil scraper ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .max. 1.00 mm seat sealing intake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .max. 1.50 mm seat sealing exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .max. 2.00 mm run out of valve heads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .max. 0.05 mm valve guides diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .max. 7.05 mm clearance outer rotor - housing . . . . . . . . . . . . . . . . . . . . . . . . . .max. 0.20 mm clearance outer rotor - inner rotor . . . . . . . . . . . . . . . . . . . . . . . .max. 0.20 mm minimum spring length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25.00 mm Length of springs . . . . . . . . . . . . . . . . . . . . . . .min. 34.5 mm (new 37.00 mm) wear limit organic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .min. 2.50 mm diameter of bearing bolt (needle bearing) . . . . . . . . . . . . . . . . . .min. 19.97 mm axial play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.10 - 0.40 mm Connecting rod bearing Cylinder 400 Cylinder 640 Piston forged Piston cast Piston rings end gap Valves Oil pumps Bypaß valve Clutch Camshaft Transmission shafts BASIC CARBURETOR SETTING Type Carb.-setting number Main jet Needle jet Idling jet Jet needle Needle clip pos. f. top Mixt. adj. screw open Throttle valve Starting jet Performance restrictor 400 LC4-E 400 LC4-E 400 LC4-E 25 kW 31 kW USA PHM 38 ND 100197 130 AR 264 50 K 23 2. from top 1.5 turns 50/1 45(50,55) slide stop 51mm PHM 38 ND 100197 130 AR 264 50 K 23 2. from top 1,5 turns 50/1 45(50,55) – BST40-225 090298 142,5 689 X-6 45 6G5 3. from top 2,25 turns – – – 640 LC4-E, Adventure 640 LC4-E, Adventure 640 Duke 25 kW 36 kW 40 kW BST40-225 080298 142,5 689 X-6 45 6G5 3. from top 2,25 turns – – slide stop 17mm BST40-225 090298 142,5 689 X-6 45 6G5 3. from top 2,25 turns – – – BASIC CARBURETOR SETTING Type Carb.-setting number Main jet Needle jet Idling jet Jet needle Needle clip pos. f. top Mixt. adj. screw open Throttle valve Starting jet Performance restrictor BST40-225 100299 145 689 X-6 45 6G5 3. from top 2,25 turns – – – 10-41D TECHNICAL SPECIFICATIONS - CHASSIS 400/640 LC4-E, 640 LC4-E SUPERMOTO 2000 400 LC4-E 640 LC4-E Frame Central chrome-moly-steel frame Fork White Power – Up Side Down 43 Wheel travel front/rear Rear suspension 270 / 300 mm (10,6 / 11,8 in) Central shock absorber (WP) with PRO-LEVER linkage to rear-swingarm with needle bearing Front brake Disc brake with carbon-steel brake disc, brake caliper floated Brake Disk front Rear brake 640 LC4-E SUPERMOTO Ø 300 mm (11,8 in) Ø 320 mm ( 12,6 in) Disc brake with carbon-steel brake disc Ø 220 mm (8,7 in), brake caliper floated Tyres front 90/90-21 120/70-17 Air press. road, driver only 1,5 bar (21 psi) 2,0 bar (28 psi) Air press. road, with passenger 2,0 bar (28 psi) 2,2 bar (31 psi) 140/80-18 160/60-17 Air press. road, driver only 2,0 bar (28 psi) 2,2 bar (31 psi) Air press. road, with passenger 2,2 bar (31 psi) 2,4 bar (34 psi) Tyres rear Fuel tank capacity 11 liter (2,9 US gallons) / 18 liter (4,75 US gallons) 2,5 liter (0,66 US gallons) reserve Art.-Nr. 3.206.006 -E Final drive ratio 15:45 17:42 Chain Lamps 5/8 x 1/4 " O-Ring head light . . . . . . . . . . . . . . . . . . . . . . . . H4 12V 60/55W (socket P43t) parking light . . . . . . . . . . . . . . . . . . . . . . 12V 5W (socket W2,1x9,5d) speedometer, tachometer light . . . . . . . . . 12V 1,2W (socket W2x4,6d) indicator lamp . . . . . . . . . . . . . . . . . . . . . 12V 1,2W (socket W2x4,6d) stop and taillight . . . . . . . . . . . . . . . . . . . 12V 21/5W (socket BaY15d) flasher . . . . . . . . . . . . . . . . . . . . . . . . . . 12V 10W (socket Ba15s) license plate illumination . . . . . . . . . . . . . 12V 5W (socket W2,1x9,5d) Battery 12V 8Ah Steering angle 62,5° Wheel base 1510 ± 10 mm (59,4 ± 0,4 in) Seat high Repair manual KTM LC4 16:42 935 mm (36,8 in) 915 mm (36 in) Ground clearance 355 mm (14 in) 335 mm (13,2 in) Dead weight without fuel 136 kg (300 lbs) 137 kg (302 lbs) Max. permissable front axe load 211 kg (466 lbs) Max. permissable rear axe load 335 kg (740 lbs) Max. permissable laden weigth 350 kg (773 lbs) STANDARD ADJUSTMENT - FORK Compression adjuster Rebound adjuster Spring Spring preload Air chamber length Capacity per fork leg Fork oil WP 0518U790 20 12 4,4 N/mm 6 mm (0,25 in) 150 mm (5,9 in) ca 410 ccm SAE5 STANDARD-ADJUSTMENT - SHOCK ABSORBER Compression adjuster Rebound adjuster Spring Spring preload WP 0118U707 6 7 66 / 260 27 mm (1,1 in) 10-42D TECHNICAL SPECIFICATIONS - CHASSIS LC4 ADVENTURE R 640 2000 LC4 Adventure R 640 Frame Central chrome-moly-steel frame Fork WP Extreme Wheel travel front/rear Rear suspension 280/320 mm (11/12,6 in) Central shock absorber (WP) with PRO-LEVER linkage to rear-swingarm with needle bearing Front brake Disc brake with carbon-steel brake disc Ø 300 mm (11,8 in), brake caliper floated Rear brake Disc brake with carbon-steel brake disc Ø 220 mm (8,7 in), brake caliper floated Tyres front 90/90-21 Enduro3 Air pressure offroad 1,5 bar (21 psi) Air press. road, driver only 2,0 bar (29 psi) Tyres rear 140/80-18 Enduro3 Air press. road, driver only 2,0 bar (29 psi) Air press. road, with passenger 2,2 bar (32 psi) Fuel tank capacity 28 liter (7,4 US gallons) of that 3,5 liter (1 US gallons) reserve Final drive ratio 16 : 42 Chain 5/8 x 1/4 " O-Ring Battery maintenance-free battery Steering angle 12V 8Ah 62,5° Wheel base 1510 ± 10 mm (59,4 ± 0,4 in) Seat high 955 mm (37,7 in) Ground clearance 375 mm (14,8 in) Dead weight without fuel 154 kg (340 lbs) Max. permissible front axle load 150 kg (331 lbs) Max. permissible rear axle load 230 kg (507 lbs) Max. permissible laden weight 380 kg (839 lbs) STANDARD ADJUSTMENT - FORK STANDARD-ADJUSTMENT - SHOCK ABSORBER 09.18.S7.55 01.18.R7.97 Compression adjuster 14 Compression adjuster 3 Rebound adjuster 12 Rebound adjuster 5 Spring 4,4 N/mm Spring preload 10 mm (0,4 in) Air chamber length 155 mm (5,9 in) Capacity per fork leg Fork oil ca 400 ccm SAE5 Spring Spring preload 70/260 23 mm (0,9 in) 10-43D TECHNICAL SPECIFICATIONS - CHASSIS Frame Fork Rear suspension Shock absorber Repair manual KTM LC4 Art.-Nr. 3.206.006 -E Front brake Rear brake Tyres Air pressure rider only Air pressure with passenger Fuel tank capacity Final drive ratio Chain Lamps Battery Steering angle Wheel base Seat high Ground clearance Dead weight without fuel Max. permissible front axle load Max. permissible rear axle load Max. permissible laden weight KTM 640 DUKE 2000 Central chrome-moly-steel frame type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP - USD 43 Multi adjuster 0518U795 wheel travel . . . . . . . . . . . . . . . . . . . . . . . . . . 140 mm (5,5 in) standard adjustment compression. . . . . . . . . . . driver only = 14, with passenger = 14 standard adjustment rebound. . . . . . . . . . . . . . driver only = 16, with passenger = 16 fork leg projection upper fork bridge . . . . . . . . 3 mm (0,12 in) oil capacity per fork leg . . . . . . . . . . . . . . . . . . appr. 400 ccm (24 cubic in) / SAE 5 air chamber lenght . . . . . . . . . . . . . . . . . . . . . 100 mm (4 in) WP central shock absorber with PRO-LEVER linkage to rear- swing-arm with needle bearing type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP central shock absorber BAVP 118Q785 rear wheel travel . . . . . . . . . . . . . . . . . . . . . . . 170 mm (6.7 in) standard adjustment compression. . . . . . . . . . . driver only = 3, with passenger = 5 standard adjustment rebound. . . . . . . . . . . . . . driver only = 5, with passenger = 3 spring preload . . . . . . . . . . . . . . . . . . . . . . . . . driver only = 23 mm (0.9 in),with passenger = 28 mm (1.1 in) spring type . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 - 260 Disc brake with carbon-steel brake disc Ø 320 mm (12,6 in) and 4-piston brake caliper Disc brake with carbon-steel brake disc Ø 220 mm (8,7 in) and single-piston brake caliper floated front: 120/70 R 17 58H rear: 160/60 R 17 69H 2.0 bar (29 psi) 2.2 bar (32 psi) 2.2 bar (32 psi) 2.4 bar (35 psi) 11 liter (2,9 US gallons), out of this 2,5 liter (0,6 US gallons) reserve 17 : 38 O-ring 5/8 x 1/4" low beam . . . . . . . . . . . . . . . . . . . . . . . . . . . . HB3 12V 65W (socket P20d) high beam . . . . . . . . . . . . . . . . . . . . . . . . . . . HB3 12V 65W (socket P20d) parking light . . . . . . . . . . . . . . . . . . . . . . . . . . 12V 5W (socket W2,1x9,5d) speedometer, tachometer light . . . . . . . . . . . . . 12V 1,2W (socket W2x4,6d) indicator lamp . . . . . . . . . . . . . . . . . . . . . . . . . 12V 1,2W (socket W2x4,6d) stop and taillight . . . . . . . . . . . . . . . . . . . . . . . 12V 21/5W (socket BaY15d) flasher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12V 10W (socket Ba15s) maintenance-free battery 12V 8Ah 64,2° 1460 ± 15 mm (57.5 ± 0.6 in) 860 mm (33.9 in) 250 mm (9.9 in) 145 kg (3 lbs) 150 kg (2 lbs) 200 kg (4 lbs) 350 kg (773 lbs) 10-44D TECHNICAL SPECIFICATIONS - CHASSIS Frame Fork Rear suspension Shock absorber Front brake Rear brake Tyres Air pressure rider only Air pressure with passenger Fuel tank capacity Final drive ratio Chain Lamps Battery Steering angle Wheel base Seat high Ground clearance Dead weight without fuel Max. permissible front axle load Max. permissible rear axle load Max. permissible laden weight 640 DUKE 2000 USA, AUS Central chrome-moly-steel frame type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP - USD 43 Top adjuster 518T780 wheel travel . . . . . . . . . . . . . . . . . . . . . . . . . . 140 mm (5,5 in) standard adjustment compression. . . . . . . . . . . driver only = 14, with passenger = 14 standard adjustment rebound. . . . . . . . . . . . . . driver only = 14, with passenger = 14 fork leg projection upper fork bridge . . . . . . . . 3 mm (0,12 in) oil capacity per fork leg . . . . . . . . . . . . . . . . . . appr. 400 ccm (45 cubic in) / SAE 5 air chamber lenght . . . . . . . . . . . . . . . . . . . . . 100 mm (4 in) WP central shock absorber with PRO-LEVER linkage to rear- swing-arm with needle bearing type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP central shock absorber BAVP 118Q785 rear wheel travel . . . . . . . . . . . . . . . . . . . . . . . 170 mm (6.7 in) standard adjustment compression. . . . . . . . . . . driver only = 3, with passenger = 5 standard adjustment rebound. . . . . . . . . . . . . . driver only = 5, with passenger = 3 spring preload . . . . . . . . . . . . . . . . . . . . . . . . . driver only = 23 mm (0.9 in),with passenger = 28 mm (1.1 in) spring type . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 - 260 Disc brake with carbon-steel brake disc Ø 320 mm (12,6 in) and 4-piston brake caliper Disc brake with carbon-steel brake disc Ø 220 mm (8,7 in) and single-piston brake caliper floated front: 120/70 R 17 58H rear: 160/60 R 17 69H 2.0 bar (29 psi) 2.2 bar (32 psi) 2.2 bar (32 psi) 2.4 bar (35 psi) 12 liter (3,2 US gallons), out of this 2,5 liter (0,6 US gallons) reserve 17 : 38 O-ring 5/8 x 1/4" low beam . . . . . . . . . . . . . . . . . . . . . . . . . . . . HB3 12V 65W (socket P20d) high beam . . . . . . . . . . . . . . . . . . . . . . . . . . . HB3 12V 65W (socket P20d) parking light . . . . . . . . . . . . . . . . . . . . . . . . . . 12V 5W (socket W2,1x9,5d) speedometer, tachometer light . . . . . . . . . . . . . 12V 1,2W (socket W2x4,6d) indicator lamp . . . . . . . . . . . . . . . . . . . . . . . . . 12V 1,2W (socket W2x4,6d) stop and taillight . . . . . . . . . . . . . . . . . . . . . . . 12V 21/5W (socket BaY15d) flasher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12V 10W (socket Ba15s) maintenance-free battery 12V 8Ah 64,2° 1460 ± 15 mm (57.5 ± 0.6 in) 860 mm (33.9 in) 250 mm (9.9 in) 145 kg (3 lbs) 150 kg (2 lbs) 200 kg (4 lbs) 350 kg (773 lbs) 10-45D Art.-Nr. 3.206.006 -E TECHNICAL SPECIFICATIONS – ENGINE 400 SXC USA 2000 Engine Design Displacement Bore / Stroke Ratio Fuel Valve timing Camshaft Valve timing by 1 mm valve clearence Valve diameter Valve clearence cold Crank shaft bearing Connecting rod bearing Top end bearing Piston Piston rings Engine lubrication Engine oil Engine oil quantity Primary ratio 400 SXC Liquid-cooled single cylinder 4-stroke engine 398 ccm 89 / 64 mm 10,8 : 1 unleaded premium gasoline with a least RON 95 4 valves over rocker arm and 1 overhead camshaft, camshaft drive through single chain 249/1 IO 22° BTDC EO 60° BBDC IC 42° ABDC EC 4° ATDC Intake: 36 mm Exhaust: 30 mm Intake: 0,20 mm Exhaust: 0,20 mm 2 cylinder roller bearing needle bearing bronze bushing cast aluminium alloy 1 compression ring, 1 taper face ring, 1 oil scraper ring forced-feed lubrication through Eaton-Oilpump with oil sump see bellow 1,45 liters (0,38 US gallons) straight geared spur wheels 30 : 81 teeth Clutch Transmission Gear ratio multi disc clutch in oil bath 5-speed claw shifted 1st 14:35 2nd 15:24 3rd 18:21 4th 20:19 5th 22:18 contactless thyristor ignition with electronic advanced system type SEM adjustment to max. 38 ° BTDC at 6000 rpm 12V 130W NGK D8EA 0,6 mm liquid cooled, permanent rotation of cooling liquid through mechanic driven water pump 1 liter, 40% antifreeze, 60% water, at least –25°C (–13°F) decompressor automatic and hand actuated, cold and hot start knob on carburetor Ignition system Ignition timing Generator Spark plug Spark plug gap Cooling system Cooling liquid Starting equipment Repair manual KTM LC4 ASSEMBLY CLEARANCE, WEAR LIMIT Crank shaft Connecting rod bearing Piston cast Piston rings end gap Valves Oil pump Bypaß valve Clutch discs Clutch springs Transmission shafts axial play..................................................0,03 - 0,12 mm run out of crank stud .................................max. 0,08 mm radial play ..................................................max. 0,05 mm axial play ...................................................max. 1,00 mm assembly clearance ...................................max. 0,05 mm compression rings ......................................max. 0,60 mm oil scraper ring ...........................................max. 0,80 mm seat sealing intake......................................max. 1,50 mm seat sealing exhaust ...................................max. 2,00 mm run out of valve heads ...............................max. 0,03 mm valve guides diameter ................................max. 7,05 mm clearance outer rotor - housing..................max. 0,20 mm clearance outer rotor - inner rotor..............max. 0,20 mm minimum spring lenght..........................................25 mm wear limit organic .................................................2,5 mm minimum lenght ...........................34,5 mm (new 37 mm) axial play......................................................0,1 - 0,4 mm (0,001-0,005 in) (0,003 in) (0,002 in) (0,04 in) (0,002 in) (0,023 in) (0,031 in) 0,059 in) (0,080 in) (0,001 in) (0,277 in) (0,008 in) (0,008 in) (1 in) (0,1 in) (1,36 in - new 1,45 in) (0,004 - 0,016 in) 10-46D TECHNICAL SPECIFICATIONS - CHASSIS 400 SXC USA 2000 400 SXC Frame Central chrome-moly-steel frame Fork White Power – EXTREME Wheel travel front/rear Rear suspension 295 / 320 mm (11,6 / 12,6 in) Central shock absorber (WP) with PRO-LEVER linkage to rear-swingarm with needle bearing Front brake Disc brake with carbon-steel brake disc Ø 260 mm (10,2 in), brake caliper floated Rear brake Disc brake with carbon-steel brake disc Ø 220 mm (8,7 in), brake caliper floated Tyres front 90/90-21 54R Air pressure offroad 1,0 bar (14 psi) Air press. road, driver only 1,5 bar (21 psi) Tyres rear 140/80-18 70R Air pressure offroad 1,2 bar (17 psi) Air press. road, driver only 2,0 bar (28 psi) Fuel tank capacity 9 liter (3 US gallons) of that 1,5 liter (0,4 US gallons) reserve Final drive ratio 15 : 50 Chain 5/8 x 1/4 " Steering angle 62,5° Wheel base 1510 ± 10 mm (59,4 ± 0,4 in) Seat high 940 mm (37 in) Ground clearance 375 mm (14,8 in) Dead weight without fuel 121 kg (267 lbs) STANDARD ADJUSTMENT - FORK STANDART-ADJUSTMENT - SHOCK ABSORBER 05.18.T7.81 Compression adjuster 10 Rebound adjuster 12 Spring 4,2 N/mm Spring preload 6 mm (0,24 in) Air chamber length 130 mm (5,1 in) Capacity per fork leg ca 350 ccm Fork oil SAE5 NOTE FOR WHITE POWER FORKS: The damping units in the left and the right fork leg are of different design. Make sure not to mix them up in case of repair or service works. BASIC CARBURETOR SETTING Type Carb.-setting number Main jet Needle jet Idling jet Jet needle Needle clip pos. f. top Mixt. adj. screw open Throttle valve Starting jet Performance restrictor BST40-225 040599 160 689 X-6 45 6G5 3. from top 2,25 turns – – – 01.18.Q7.82 Compression adjuster 3 Rebound adjuster 4 Spring 63/260 Spring preload 23 mm 10-47D TECHNICAL SPECIFICATIONS – ENGINE 620 SC, 620 SC SUPERMOTO 2001 Art.-Nr. 3.206.006 -E Engine Design Displacement Bore / Stroke Ratio Fuel Valve timing Camshaft Valve diameter Valve clearence cold Crank shaft bearing Connecting rod bearing Top end bearing Piston Piston rings Engine lubrication Engine oil Engine oil quantity Primary ratio Clutch Transmission Gear ratio Ignition system Ignition timing Generator Spark plug Spark plug gap Cooling system Cooling liquid Starting equipment 620 Liquid-cooled single cylinder 4-stroke engine with balancer shaft 609 ccm 101 / 76 mm 10,4 : 1 unleaded premium gasoline with a least RON 95 4 valves over rocker arm and 1 overhead camshaft, camshaft drive through single chain 249/1 Intake: 36 mm Exhaust: 30 mm Intake: 0,15 mm Exhaust: 0,15 mm 2 cylinder roller bearing needle bearing bronze bushing forged aluminium 1 compression ring, 1 taper face ring, 1 oil scraper ring forced-feed lubrication through Eaton-Oilpump with oil sump see table 1,6 liters (0,42 US gallons) straight geared spur wheels 30 : 81 teeth multi disc clutch in oil bath 5-speed claw shifted 1st 14:35 2nd 15:24 3rd 18:21 4th 20:19 5th 22:18 contactless thyristor ignition with electronic advanced system type KOKUSAN 4K3 adjustment to max. 36 ° BTDC at 5000 rpm 12V 110W NGK DPR8 EA-9 0,9 mm liquid cooled, permanent rotation of cooling liquid through mechanic driven water pump 1 liter, 40% antifreeze, 60% water, at least –25°C (–13°F) decompressor automatic and hand actuated, cold and hot start knob on carburetor BASIC CARBURETOR SETTING Repair manual KTM LC4 620 SC, 620 SC SUPERMOTO Carburetor Carburetor setting number Main jet Needle jet Idling jet Jet needle Needle position from top Mixture.adju. screw open Throttle valve Starting jet Performance restrictor PHM 40 SD 080600 155 DR 266 45 K 51 3 rd 1,5 turns 40 45 Slide stop 24mm 10-48D ASSEMBLY CLEARANCE, WEAR LIMIT Crank shaft Connecting rod bearing Piston forged Piston rings end gap Valves Oil pump Bypaß valve Clutch discs Clutch springs Transmission shafts axial play..................................................0,03 - 0,12 mm run out of crank stud .................................max. 0,04 mm radial play ..................................................max. 0,05 mm axial play ...................................................max. 1,00 mm assembly clearance ...................................max. 0,12 mm compression rings ......................................max. 0,60 mm oil scraper ring ...........................................max. 0,80 mm seat sealing intake......................................max. 1,50 mm seat sealing exhaust ...................................max. 2,00 mm run out of valve heads ...............................max. 0,03 mm valve guides diameter ................................max. 7,05 mm clearance outer rotor - housing..................max. 0,20 mm clearance outer rotor - inner rotor..............max. 0,20 mm minimum spring lenght..........................................25 mm wear limit organic .................................................2,5 mm minimum lenght ...........................34,5 mm (new 37 mm) axial play......................................................0,1 - 0,4 mm API: SG, SH TEMPERATURE – 10W 40 10W 50 + 0°C 32°F 15W 40 15W 50 Engine oil Use only oil brands, which meet quality requirements (Shell Advance Ultra 4) of API-classes SG or SH (informations on bottles) or higher. ! POOR CAUTION ! OIL QUALITY OR MINOR QUANTITY EFFECT EARLY ENGINE-WEAR. (0,001-0,005 in) (0,002 in) (0,002 in) (0,04 in) (0,005 in) (0,023 in) (0,031 in) 0,059 in) (0,080 in) (0,001 in) (0,277 in) (0,008 in) (0,008 in) (1 in) (0,1 in) (1,36 in - new 1,45 in) (0,004 - 0,016 in) 10-49D TECHNICAL SPECIFICATIONS - CHASSIS 620 SC, 620 SC SUPERMOTO 2001 620 SC 620 SC SUPERMOTO Frame Central chrome-moly-steel frame Fork White Power – Up Side Down 43 Wheel travel front/rear Rear suspension 295 / 320 mm (11,6 / 12,6 in) Central shock absorber (WP) with PRO-LEVER linkage to rear-swingarm with needle bearing Front brake Disc brake with carbon-steel brake disc, brake caliper floated Brake Disk Ø 260 mm (10,2 in) Rear brake Disc brake with carbon-steel brake disc Ø 220 mm (8,7 in), brake caliper floated Tyres front 90/90-21 120/70-17 Air pressure offroad 1,0 bar (14 psi) – Air press. road, driver only 1,8 bar (21 psi) 2,0 bar (28 psi) Tyres rear 140/80-18 160/60-17 Air pressure offroad 1,2 bar (17 psi) – Air press. road, driver only 2,0 bar (28 psi) 2,2 bar (32 psi) Fuel tank capacity 9 liter (2,38 US gallons) of that 2,5 liter (0,66 US gallons) reserve Final drive ratio 16:40 Chain 62,5° Wheel base 1510 ± 10 mm (59,4 ± 0,4 in) Seat high Art.-Nr. 3.206.006 -E 17:38 5/8 x 1/4 " O-Ring Steering angle 940 mm (37 in) 920 mm (36 in) Ground clearance 375 mm (14,8 in) 355 mm (14 in) Dead weight without fuel 122 kg (269 lbs) 123 kg (271 lbs) STANDARD ADJUSTMENT - FORK Compression adjuster Rebound adjuster Spring Spring preload Air chamber length Fork oil Repair manual KTM LC4 Ø 320 mm ( 12,6 in) 620 SC WP 0518V706 14 12 4,2 N/mm 6 mm 150 mm SAE 5 SC SUPERMOTO WP 0518V721 14 14 5,0 N/mm 9 mm 130 mm SAE 5 STANDARD-ADJUSTMENT - SHOCK ABSORBER Compression adjuster Rebound adjuster Spring Spring preload 620 SC WP 0118V712 3 5 63 / 260 23 mm SC SUPERMOTO WP 0118V720 5 7 75 / 260 15 mm 10-50D TECHNICAL DATA – ENGINE 400/640 LC4-E, 640 ADVENTURE, DUKE 2001 Type Design Displacement Bore / Stroke Ratio Fuel Valve timing Camshaft Valve diameter Valve clearence cold Crank shaft bearing Connecting rod bearing Top end bearing Piston Piston rings Engine lubrication Quantity of engine oil Engine oil Primary ratio Clutch Transmission Ignition system Ignition timing Generator Spark plug Spark plug gap Cooling system Cooling liquid Starting equipment 400 LC4-E 640 LC4-E Liquid-cooled single cylinder 4-stroke engine with balancer shaft and electric starter 398 ccm 624,6 ccm 89 / 64 mm 101 / 78 mm 10,8 : 1 11,0 : 1 unleaded premium gasoline with a least RON 95 4 valves over rocker arm and 1 overhead camshaft, camshaft drive through single chain 249/1 Intake: 36 mm Exhaust: 30 mm Intake: 0.20 mm Exhaust: 0.20 mm Intake: 0.15 mm Exhaust: 0.15 mm 2 cylinder roller bearing needle bearing bronze bushing forged/cast aluminium alloy 1 compression ring, 1 taper face ring, 1 oil scraper ring 2 Eaton-Oilpumps see table 2.1 liters including frame straight geared spur wheels 30 : 81 teeth multi disc clutch in oil bath 5-speed claw shifted contactless DC- CDI ignition with digital advanced system type KOKUSAN adjustment to max. 38° BTDC at 6000 rpm 12V 200W NGK DPR8 EA9 0.9 mm liquid cooled, permanent rotation of cooling liquid through mechanic driven water pump 1 liter, 40% antifreeze, 60% water, at least –25° C (–13° F) electric starter, kick starter ASSEMBLY CLEARANCE, WEAR LIMIT Crank shaft Connecting rod bearing Cylinder 400 Cylinder 640 Piston forged Piston cast Piston rings end gap Valves Oil pumps Bypaß valve Clutch Camshaft Transmission shafts axial play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.03 - 0.12 mm run out of crank stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .max. 0.08 mm radial play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .max. 0.05 mm axial play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .max. 1.10 mm bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .max. 89.04 mm bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .max. 101.04 mm assembly clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .max. 0.12 mm assembly clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .max. 0.05 mm compression rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .max. 0.80 mm oil scraper ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .max. 1.00 mm seat sealing intake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .max. 1.50 mm seat sealing exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .max. 2.00 mm run out of valve heads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .max. 0.05 mm valve guides diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .max. 7.05 mm clearance outer rotor - housing . . . . . . . . . . . . . . . . . . . . . . . . . .max. 0.20 mm clearance outer rotor - inner rotor . . . . . . . . . . . . . . . . . . . . . . . .max. 0.20 mm minimum spring length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25.00 mm Length of springs . . . . . . . . . . . . . . . . . . . . . . .min. 34.5 mm (new 37.00 mm) wear limit organic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .min. 2.50 mm diameter of bearing bolt (needle bearing) . . . . . . . . . . . . . . . . . .min. 19.97 mm axial play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.10 - 0.40 mm 10-51D GEAR RATIOS Primary ratio Transmission 1st gear 2nd gear 3rd gear 4th gear 5th gear 30:81 Original final drive ratio Available chain drive sprockets Available final drive sprockets 15:45 16:42 17:38 17:42 15 t 16 t for chain 17 t 5/8 x 1/4" 38 40 42 45 48 14:35 15:24 18:21 20:19 22:18 t t for chain t 5/8 x 1/4" t t Engine oil Use only oil brands, which meet quality requirements (Shell Advance Ultra 4) of API-classes SG or SH (informations on bottles) or higher. API: SG, SH TEMPERATURE – Repair manual KTM LC4 Art.-Nr. 3.206.006 -E 10W 40 10W 50 0°C 32°F + ! POOR CAUTION 15W 40 15W 50 BASIC CARBURETOR SETTING Type Carb.-setting number Main jet Needle jet Idling jet Jet needle Needle clip pos. f. top Mixt. adj. screw open Throttle valve Starting jet Performance restrictor 400 LC4-E 400 LC4-E 25 kW 31 kW 400 LC4-E USA PHM 38 ND 100197 130 AR 264 50 K 23 2. from top 1.5 turns 50/1 45(50,55) slide stop 51mm PHM 38 ND 100197 130 AR 264 50 K 23 2. from top 1,5 turns 50/1 45(50,55) – BST40-225 090298 142,5 689 X-6 45 6G5 3. from top 2,25 turns – – – 640 LC4-E, Adventure 640 LC4-E, Adventure 640 Duke 25 kW 36 kW 40 kW BST40-225 080298 142,5 689 X-6 45 6G5 3. from top 2,25 – – slide stop 17mm BST40-225 090298 142,5 689 X-6 45 6G5 3. from top 2,25 – – – BASIC CARBURETOR SETTING Type Carb.-setting number Main jet Needle jet Idling jet Jet needle Needle clip pos. f. top Mixt. adj. screw open Throttle valve Starting jet Performance restrictor ! OIL QUALITY OR MINOR QUANTITY EFFECT EARLY ENGINE-WEAR. BST40-225 100299 145 689 X-6 45 6G5 3. from top 2,25 – – – 10-52D TECHNICAL SPECIFICATIONS - CHASSIS 400/640 LC4-E, 640 LC4-E SUPERMOTO 2001 400 LC4-E 640 LC4-E 640 LC4-E SUPERMOTO Frame Central chrome-moly-steel frame Fork White Power – Up Side Down 43 Wheel travel front/rear 270 / 300 mm (10,6 / 11,8 in) Rear suspension Central shock absorber (WP) with PRO-LEVER linkage to rear-swingarm with needle bearing Front brake Disc brake with carbon-steel brake disc, brake caliper floated Brake Disk front Ø 300 mm (11,8 in) Rear brake Ø 320 mm ( 12,6 in) Disc brake with carbon-steel brake disc Ø 220 mm (8,7 in), brake caliper floated 90/90-21 120/70-17 Air press. road, driver only Tyres front 1,5 bar (21 psi) 2,0 bar (28 psi) Air press. road, with passenger 2,0 bar (28 psi) 2,2 bar (31 psi) 140/80-18 160/60-17 Air press. road, driver only 2,0 bar (28 psi) 2,2 bar (31 psi) Air press. road, with passenger 2,2 bar (31 psi) 2,4 bar (34 psi) Tyres rear Fuel tank capacity 11 liter (2,9 US gallons) / 18 liter (4,75 US gallons) 2,5 liter (0,66 US gallons) reserve Final drive ratio 15:45 16:42 17:42 Chain Lamps 5/8 x 1/4 " O-Ring head light . . . . . . . . . . . . . . . . . . . . . . . . H4 12V 60/55W (socket P43t) parking light . . . . . . . . . . . . . . . . . . . . . . 12V 5W (socket W2,1x9,5d) speedometer, tachometer light . . . . . . . . . 12V 1,2W (socket W2x4,6d) indicator lamp . . . . . . . . . . . . . . . . . . . . . 12V 1,2W (socket W2x4,6d) stop and taillight . . . . . . . . . . . . . . . . . . . 12V 21/5W (socket BaY15d) flasher . . . . . . . . . . . . . . . . . . . . . . . . . . 12V 10W (socket Ba15s) license plate illumination . . . . . . . . . . . . . 12V 5W (socket W2,1x9,5d) Battery 12V 8Ah Steering angle 62,5° Wheel base 63° 1510 ± 10 mm (59,4 ± 0,4 in) Seat high 955 mm (37,6 in) 935 mm (36,8 in) Ground clearance 355 mm (14 in) 335 mm (13,2 in) Dead weight without fuel 136 kg (300 lbs) 137 kg (302 lbs) Max. permissable front axe load 211 kg (466 lbs) Max. permissable rear axe load 335 kg (740 lbs) Max. permissable laden weigth 350 kg (773 lbs) STANDARD ADJUSTMENT - FORK 400/640 LC4-E Compression adjuster Rebound adjuster Spring Spring preload Air chamber length Fork oil WP 0518V707 20 12 4,4 N/mm 6 mm 150 mm SAE 5 640 LC4-E SUPERMOTO WP 0518V721 14 14 5,0 N/mm 9 mm 130 mm SAE 5 STANDARD-ADJUSTMENT - SHOCK ABSORBER 400/640 LC4-E Compression adjuster Rebound adjuster Spring Spring preload WP 0118V710 6 7 66 / 260 27 mm 640 LC4-E SUPERMOTO WP 0118V720 5 7 75 / 260 15 mm 10-53D TECHNICAL SPECIFICATIONS - CHASSIS 640 LC4 ADVENTURE 2001 640 LC4 Adventure Frame Central chrome-moly-steel frame Fork WP USD Wheel travel front/rear Rear suspension 275/300 mm (10,5/12 in) Central shock absorber (WP) with PRO-LEVER linkage to rear-swingarm with needle bearing Front brake Disc brake with carbon-steel brake disc Ø 320 mm (11,8 in), brake caliper floated Rear brake Disc brake with carbon-steel brake disc Ø 220 mm (8,7 in), brake caliper floated Tyres front 90/90-21 Enduro3 Air pressure offroad 1,8 bar (21 psi) Air press. road, driver only 2,0 bar (29 psi) Tyres rear 140/80-18 Enduro3 Air press. road, driver only 2,0 bar (29 psi) Air press. road, with passenger 2,2 bar (32 psi) Fuel tank capacity 28 liter (7,4 US gallons) of that 3,5 liter (1 US gallons) reserve Final drive ratio 16 : 42 Chain 5/8 x 1/4 " O-Ring Battery maintenance-free battery Steering angle Art.-Nr. 3.206.006 -E Wheel base 1510 ± 10 mm (59,4 ± 0,4 in) Seat high 955 mm (37,7 in) Ground clearance 355 mm (14,2 in) Dead weight without fuel 154 kg (340 lbs) Max. permissible front axle load 150 kg (331 lbs) Max. permissible rear axle load 230 kg (507 lbs) Max. permissible laden weight 380 kg (839 lbs) STANDARD ADJUSTMENT - FORK STANDARD-ADJUSTMENT - SHOCK ABSORBER 14.18.V704 14 Compression adjuster Rebound adjuster 14 Rebound adjuster Spring preload Air chamber length Repair manual KTM LC4 01.18.V709 Compression adjuster Spring Capacity per fork leg Fork oil 12V 8Ah 62,5° 4,4 N/mm 4 mm 120 mm ca 420 ccm SAE 5 Spring Spring preload 3 5 66/260 27 mm (0,9 in) 10-54D TECHNICAL SPECIFICATIONS - CHASSIS Frame Fork Rear suspension Shock absorber Front brake Rear brake Tyres Air pressure rider only Air pressure with passenger Fuel tank capacity Final drive ratio Chain Lamps Battery Steering angle Wheel base Seat high Ground clearance Dead weight without fuel Max. permissible front axle load Max. permissible rear axle load Max. permissible laden weight KTM 640 DUKE 2001 Central chrome-moly-steel frame type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP - USD 43 Multi adjuster 0518U795 wheel travel . . . . . . . . . . . . . . . . . . . . . . . . . . 140 mm (5,5 in) standard adjustment compression. . . . . . . . . . . driver only = 14, with passenger = 14 standard adjustment rebound. . . . . . . . . . . . . . driver only = 16, with passenger = 16 fork leg projection upper fork bridge . . . . . . . . 3 mm (0,12 in) oil capacity per fork leg . . . . . . . . . . . . . . . . . . appr. 400 ccm (24 cubic in) / SAE 5 air chamber lenght . . . . . . . . . . . . . . . . . . . . . 100 mm (4 in) WP central shock absorber with PRO-LEVER linkage to rear- swing-arm with needle bearing type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP central shock absorber BAVP 118Q785 rear wheel travel . . . . . . . . . . . . . . . . . . . . . . . 170 mm (6.7 in) standard adjustment compression. . . . . . . . . . . driver only = 3, with passenger = 5 standard adjustment rebound. . . . . . . . . . . . . . driver only = 5, with passenger = 3 spring preload . . . . . . . . . . . . . . . . . . . . . . . . . driver only = 23 mm (0.9 in),with passenger = 28 mm (1.1 in) spring type . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 - 260 Disc brake with carbon-steel brake disc Ø 320 mm (12,6 in) and 4-piston brake caliper Disc brake with carbon-steel brake disc Ø 220 mm (8,7 in) and single-piston brake caliper floated front: 120/70 R 17 58H rear: 160/60 R 17 69H 2.0 bar (29 psi) 2.2 bar (32 psi) 2.2 bar (32 psi) 2.4 bar (35 psi) 11 liter (2,9 US gallons), out of this 2,5 liter (0,6 US gallons) reserve 17 : 38 O-ring 5/8 x 1/4" low beam . . . . . . . . . . . . . . . . . . . . . . . . . . . . HB3 12V 65W (socket P20d) high beam . . . . . . . . . . . . . . . . . . . . . . . . . . . HB3 12V 65W (socket P20d) parking light . . . . . . . . . . . . . . . . . . . . . . . . . . 12V 5W (socket W2,1x9,5d) speedometer, tachometer light . . . . . . . . . . . . . 12V 1,2W (socket W2x4,6d) indicator lamp . . . . . . . . . . . . . . . . . . . . . . . . . 12V 1,2W (socket W2x4,6d) stop and taillight . . . . . . . . . . . . . . . . . . . . . . . 12V 21/5W (socket BaY15d) flasher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12V 10W (socket Ba15s) maintenance-free battery 12V 8Ah 64,2° 1460 ± 15 mm (57.5 ± 0.6 in) 860 mm (33.9 in) 250 mm (9.9 in) 145 kg (3 lbs) 150 kg (2 lbs) 200 kg (4 lbs) 350 kg (773 lbs) 10-55D TECHNICAL SPECIFICATIONS - CHASSIS Frame Fork Rear suspension Shock absorber Repair manual KTM LC4 Art.-Nr. 3.206.006 -E Front brake Rear brake Tyres Air pressure rider only Air pressure with passenger Fuel tank capacity Final drive ratio Chain Lamps Battery Steering angle Wheel base Seat high Ground clearance Dead weight without fuel Max. permissible front axle load Max. permissible rear axle load Max. permissible laden weight 640 DUKE 2001 USA, AUS Central chrome-moly-steel frame type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP - USD 43 Top adjuster 518T780 wheel travel . . . . . . . . . . . . . . . . . . . . . . . . . . 140 mm (5,5 in) standard adjustment compression. . . . . . . . . . . driver only = 14, with passenger = 14 standard adjustment rebound. . . . . . . . . . . . . . driver only = 14, with passenger = 14 fork leg projection upper fork bridge . . . . . . . . 3 mm (0,12 in) oil capacity per fork leg . . . . . . . . . . . . . . . . . . appr. 400 ccm (45 cubic in) / SAE 5 air chamber lenght . . . . . . . . . . . . . . . . . . . . . 100 mm (4 in) WP central shock absorber with PRO-LEVER linkage to rear- swing-arm with needle bearing type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP central shock absorber BAVP 118Q785 rear wheel travel . . . . . . . . . . . . . . . . . . . . . . . 170 mm (6.7 in) standard adjustment compression. . . . . . . . . . . driver only = 3, with passenger = 5 standard adjustment rebound. . . . . . . . . . . . . . driver only = 5, with passenger = 3 spring preload . . . . . . . . . . . . . . . . . . . . . . . . . driver only = 23 mm (0.9 in),with passenger = 28 mm (1.1 in) spring type . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 - 260 Disc brake with carbon-steel brake disc Ø 320 mm (12,6 in) and 4-piston brake caliper Disc brake with carbon-steel brake disc Ø 220 mm (8,7 in) and single-piston brake caliper floated front: 120/70 R 17 58H rear: 160/60 R 17 69H 2.0 bar (29 psi) 2.2 bar (32 psi) 2.2 bar (32 psi) 2.4 bar (35 psi) 12 liter (3,2 US gallons), out of this 2,5 liter (0,6 US gallons) reserve 17 : 38 O-ring 5/8 x 1/4" low beam . . . . . . . . . . . . . . . . . . . . . . . . . . . . HB3 12V 65W (socket P20d) high beam . . . . . . . . . . . . . . . . . . . . . . . . . . . HB3 12V 65W (socket P20d) parking light . . . . . . . . . . . . . . . . . . . . . . . . . . 12V 5W (socket W2,1x9,5d) speedometer, tachometer light . . . . . . . . . . . . . 12V 1,2W (socket W2x4,6d) indicator lamp . . . . . . . . . . . . . . . . . . . . . . . . . 12V 1,2W (socket W2x4,6d) stop and taillight . . . . . . . . . . . . . . . . . . . . . . . 12V 21/5W (socket BaY15d) flasher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12V 10W (socket Ba15s) maintenance-free battery 12V 8Ah 64,2° 1460 ± 15 mm (57.5 ± 0.6 in) 860 mm (33.9 in) 250 mm (9.9 in) 145 kg (3 lbs) 150 kg (2 lbs) 200 kg (4 lbs) 350 kg (773 lbs) 10-56D TECHNICAL SPECIFICATIONS – ENGINE 625 SC, 625 SC SUPERMOTO 2002 Engine Design Displacement Bore / Stroke Ratio Fuel Valve timing Camshaft Valve diameter Valve clearence cold Crank shaft bearing Connecting rod bearing Top end bearing Piston Piston rings Engine lubrication Engine oil Engine oil quantity Primary ratio Clutch Transmission Gear ratio Ignition system Ignition timing Generator Spark plug Spark plug gap Cooling system Cooling liquid Starting equipment 625 LC4 Liquid-cooled single cylinder 4-stroke engine with balancer shaft 625 ccm 101 / 78 mm 11,0 : 1 unleaded premium gasoline with a least RON 95 4 valves over rocker arm and 1 overhead camshaft, camshaft drive through single chain 249/1 Intake: 36 mm Exhaust: 30 mm Intake: 0,15 mm Exhaust: 0,15 mm 2 cylinder roller bearing needle bearing bronze bushing forged aluminium alloy 1 compression ring, 1 taper face ring, 1 oil scraper ring two oilpumps 10W-40 (Shell Advance Ultra 4) 1,6 liters (0,42 US gallons) straight geared spur wheels 30 : 81 teeth multi disc clutch in oil bath 5-speed claw shifted 1st 14:35 2nd 15:24 3rd 18:21 4th 20:19 5th 22:18 contactless DC-CDI ignition with digital advanced system type KOKUSAN 4K-3C adjustment to max. 38 ° BTDC at 6000 rpm 12V 150 W NGK DPR8 EA-9 0,9 mm liquid cooled, permanent rotation of cooling liquid through mechanic driven water pump 1 liter, 40% antifreeze, 60% water, at least –25°C (–13°F) Kickstarter, cold start knob on carburetor BASIC CARBURETOR SETTING 625 SC, 625 SC SUPERMOTO Carburetor Carburetor setting number Main jet Needle jet Idling jet Main air jet Idling air jet Needle position from top Throttle valve Starting jet Performance restrictor Stop pump membrane Keihin FCR41 140501 180 OBDVT 45 200 100 5th 15 85 Slide stop 23mm 3,2mm 10-57D TECHNICAL SPECIFICATIONS - CHASSIS 625 SC, 625 SC SUPERMOTO 2002 625 SC Art.-Nr. 3.206.006 -E Frame Fork Wheel travel front/rear Rear suspension Front brake Front brake disc Rear brake Tyres front Air press. offroad Air press. road Tyres rear Air press offroad Air press. road Fuel tank capacity Final drive ratio Chain Bulps Steering angle Wheel base Seat high Ground clearance Dead weight without fuel 625 SC SUPERMOTO Central chrome-moly-steel frame White Power 4357 MXMA 295 / 320 mm (11,8 / 12,8 in) 270 / 320 (10,8 / 12.8 in) Central shock absorber (WP BAVP3612) with PRO-LEVER linkage to rear- swing-arm with needle bearing Disc brake with carbon-steel brake disc, brake caliper floated Ø 260 mm (10,4 in) Ø 320 mm (12.8 in) Disc brake with carbon-steel brake disc 220 mm (8.8 in), brake caliper floated 90/90-21 120/70-17 1,0 bar (14 psi) 1,8 bar (26 psi) 2,0 bar (29 psi) 140/80-18 160/60-17 1,2 bar (17 psi) 2,0 bar (29 psi) 2,2 bar (32 psi) 9 liter (2,3 US gallons), 1.5 liter (0,4 US gallons) reserve 16:40 (15:50) t 17:38t X – Ring 5/8 x 1/4" headlight . . . . . . . . . . . . . H4 12V 60/55W (socket P43t) parking light . . . . . . . . . . . 12V 5W (socket W2,1x9,5d) indicator lamps . . . . . . . . . 12V 1,2W (socket W2x4,6d) brake – rear light . . . . . . . 12V 21/5 W (socket BaY15d) flasher light . . . . . . . . . . . 12V 10W (socket Ba15s) license plate illmination . . . 12V 5W (socket W2,1x9,5 d) 62,5 ° 63° 1510 ± 10 mm (59.4 ± 0.4 in) 950 mm (38 in) 920 mm (36.8 in) 340 mm (13,6 in) 300 mm (12 in) 122 kg (269 lbs) 123 kg (271 Ibs) Repair manual KTM LC4 STANDARD ADJUSTMENT - FORK Compression adjuster Rebound adjuster Spring Spring preload Air chamber length Fork oil 625 SC 625 SC SUPERMOTO WP 0518W712 WP 0518W722 20 14 12 14 4,2 N/mm 5,0 N/mm 5 mm 9 mm 140 mm 130 mm SAE 5 SAE 5 STANDARD-ADJUSTMENT - SHOCK ABSORBER Compression adjuster Rebound adjuster Spring Spring preload 625 SC WP 0118W714 3 5 63 / 260 23 mm 625 SC SUPERMOTO WP 0118W721 5 7 75 / 260 15 mm 10-58D TECHNICAL DATA – ENGINE 640 LC4 Engine Design Displacement Bore / Stroke Ratio Fuel Valve timing Camshaft Valve diameter Valve clearence cold Crank shaft bearing Connecting rod bearing Top end bearing Piston Piston rings Engine lubrication Engine oil Engine oil quantity Primary ratio Clutch Transmission Gear ratio Ignition system Ignition timing Generator Spark plug Spark plug gap Cooling system Cooling liquid Starting equipment 640 LC4 Liquid-cooled single cylinder 4-stroke engine with balancer shaft and electric starter 624,6 ccm 101 / 78 mm 11 : 1 unleaded premium gasoline with a least RON 95 4 valves over rocker arm and 1 overhead camshaft, camshaft drive through single chain 249/1 Intake: 36 mm Exhaust: 30 mm 0,15 mm Exhaust: 0,15 mm 2 cylinder roller bearing needle bearing bronze bushing forged aluminium alloy 1 compression ring, 1 taper face ring, 1 oil scraper ring two oilpumps 10W-40 (Shell Advance Ultra 4) appr. 2,1 liters including frame straight geared spur wheels 30 : 81 teeth multi disc clutch in oil bath 5-speed claw shifted 1st 14:35 2nd 15:24 3rd 18:21 4th 20:19 5th 22:18 contactless DC-CDI ignition with digital advanced system type KOKUSAN 4K-2 adjustment to max. 38° BTDC at 6000 rpm 12V 200W NGK DPR8 EA9 0,9 mm liquid cooled, permanent rotation of cooling liquid through mechanic driven water pump 1 liter, 40% antifreeze, 60% water, at least –25 ° C (–13 ° F) electric starter and kickstarter BASIC CARBURETOR SETTING Type Carb.-setting number Main jet Needle jet Idling jet Jet needle Needle clip pos. f. top Mixt. adj. screw open 2002 640 LC4, SUPERMOTO 640 LC4 ADVENTURE 640 DUKE 40 kW BST40-225 090298 142,5 689 X-6 45 6G5 3. 2,25 BST40-225 100299 145 689 X-6 45 6G5 3. 2,25 10-59D TECHNICAL SPECIFICATIONS - CHASSIS 640 LC4, 640 LC4 SUPERMOTO 2002 640 LC4 Repair manual KTM LC4 Art.-Nr. 3.206.006 -E Frame Fork Wheel travel front/rear Rear suspension Front brake Front brake disc Rear brake Tyres front Air press. road, driver only Air press. road with passenger Tyres rear Air press. road, driver only Air press. road with passenger Fuel tank capacity Final drive ratio Chain Bulps Battery Steering angle Wheel base Seat high Ground clearance Dead weight without fuel Max. permissible front axle load Max. permissible rear axle load Max. permissible laden weight 640 LC4 Supermoto Central chrome-moly-steel frame White Power – Up Side Down 4357 MXMA 270 / 300 mm (10,6 / 11.8 in) Central shock absorber (WP BAVP3612) with PRO-LEVER linkage to rear- swing-arm with needle bearing Disc brake with carbon-steel brake disc, brake caliper floated Ø 300 mm (11.8 in) Ø 320 mm (12.6 in) Disc brake with carbon-steel brake disc 220 mm (8.7 in), brake caliper floated 90/90-21 120/70-17 1.8 bar (26 psi) 2.0 bar (29 psi) 2.0 bar (29 psi) 2.2 bar (31 psi) 140/80-18 160/60-17 2.0 bar (29 psi) 2.2 bar (31 psi) 2.2 bar (31 psi) 2.4 bar (34 psi) 11 or 18 liter (2.9 or 4.8 US gallons), 2.5 liter (0,6 US gallons) reserve 16:42t 17:42t X – Ring 5/8 x 1/4" headlight . . . . . . . . . . . . . H4 12V 60/55W (socket P43t) parking light . . . . . . . . . . . 12V 5W (socket W2,1x9,5d) instrument lights . . . . . . . . 12V 1,2W (socket W2x4,6d) indicator lamps . . . . . . . . . 12V 1,2W (socket W2x4,6d) brake – rear light . . . . . . . 12V 21/5 W (socket BaY15d) flasher light . . . . . . . . . . . 12V 10W (socket Ba15s) license plate illmination . . . 12V 5W (socket W2,1x9,5 d) maintenance-free battery 12V 8Ah 62,5 ° 63° 1510 ± 10 mm (59.4 ± 0.4 in) 940 mm (37.6 in) 910 mm (36.4 in) 355 mm (14.0 in) 335 mm (13.2 in) 136kg (300 lbs) 137 kg (302 Ibs) 211 kg (465 lbs) 335 kg (740 lbs) 350 kg (773 lbs) STANDARD ADJUSTMENT - FORK 640 LC4 Compression adjuster Rebound adjuster Spring Spring preload Air chamber length Fork oil WP 0518W714 20 12 4,2 N/mm 6 mm (0,24in) 150 mm (5,9in) SAE 5 640 LC4 SUPERMOTO WP 0518W722 14 14 5,0 N/mm 9 mm (0,36in) 130 mm (5,1in) SAE 5 STANDARD-ADJUSTMENT - SHOCK ABSORBER 640 LC4 Compression adjuster Rebound adjuster Spring Spring preload WP 0118W724 3 7 66 / 260 23,5 mm(0,94in) 640 LC4 SUPERMOTO WP 0118W721 5 7 75 / 260 15 mm(0,6in) 10-60D TECHNICAL SPECIFICATIONS - CHASSIS 640 LC4 ADVENTURE Frame Fork Wheel travel front/rear Rear suspension bearing Front brake Rear brake Tyres front Air pressure offroad Air press. road, driver only Tyres rear Air press. road, driver only Air press. road, with passenger Fuel tank capacity Final drive ratio Chain Lampenbestückung Battery Steering angle Wheel base Seat high Ground clearance Dead weight without fuel Max. permissible front axle load Max. permissible rear axle load Max. permissible laden weight 640 LC4 Adventure Central chrome-moly-steel frame WP USD MXMA 4860 275/300 mm (10,5/12 in) Central shock absorber (WP BAVP3612) with PRO-LEVER linkage to rear-swingarm with need Disc brake with carbon-steel brake disc Ø 320 mm (11,8 in), brake caliper floated Disc brake with carbon-steel brake disc Ø 220 mm (8,7 in), brake caliper floated 90/90-21 Enduro3 1,8 bar (21 psi) 2,0 bar (29 psi) 140/80-18 Enduro3 2,0 bar (29 psi) 2,2 bar (32 psi) 28 liter (7,4 US gallons) of that 2 liter (0,5 US gallons) reserve 16 : 42 5/8 x 1/4 "X-Ring head light . . . . . . . . . . . . . . . . . . . . . .H1 12V 55W (Sockel P14,5S) parking light . . . . . . . . . . . . . . . . . . . .12V 2W (Sockel Ba9s) brake- rear light . . . . . . . . . . . . . . . . .12V 21/5W (Sockel BaY15d) flasher light . . . . . . . . . . . . . . . . . . . . .12V 10W (Sockel Ba15s) license plate illintion . . . . . . . . . . . . . .12V 5W (Sockel W2,1x9,5d) maintenance-free battery 12V 8Ah 62,5° 1510 ± 10 mm (59,4 ± 0,4 in) 955 mm (37,7 in) 355 mm (14,2 in) 154 kg (340 lbs) 150 kg (331 lbs) 230 kg (507 lbs) 380 kg (839 lbs) STANDARD ADJUSTMENT - FORK Compression adjuster Rebound adjuster Spring Spring preload Air chamber length Capacity per fork leg Fork oil 2002 WP 4860 MXMA 1418W711 14 14 4,4 N/mm 4 mm 120 mm approx. 420 ccm SAE 5 STANDARD-ADJUSTMENT - SHOCK ABSORBER Compression adjuster Rebound adjuster Spring Spring preload WP BAVP3612 0118W715 6 7 70/260 27 mm (0,9 in) 10-61D TECHNICAL SPECIFICATIONS - CHASSIS Frame Fork Rear suspension Shock absorber 0118W71 640 DUKE II 2002 Central chrome-moly-steel frame type . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 4357 ROMA 0518716 wheel travel . . . . . . . . . . . . . . . . . . . . . . 140 mm (5,5 in) standard adjustment compression. . . . . . . driver only = 14, with passenger = 14 standard adjustment rebound. . . . . . . . . . driver only = 16, with passenger = 16 fork leg projection upper fork bridge . . . . 3 mm (0,12 in) oil capacity per fork leg . . . . . . . . . . . . . . appr. 400 ccm (24 cubic in) / SAE 5 air chamber lenght . . . . . . . . . . . . . . . . . 100 mm (4 in) WP central shock absorber with PRO-LEVER linkage to rear- swing-arm with needle bearing type . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP central shock absorber BAVP 4681 rear wheel travel . . . . . . . . . . . . . standard adjustment compression. standard adjustment rebound. . . . spring preload . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170 mm (6.7 in) driver only = 3, with passenger = 5 driver only = 5, with passenger = 3 driver only = 23 mm (0.9 in),with passenger = 28 Repair manual KTM LC4 Art.-Nr. 3.206.006 -E mm (1.1 in) Front brake Rear brake Tyres Air pressure rider only Air pressure with passenger Fuel tank capacity Final drive ratio Chain Lamps Battery Steering angle Wheel base Seat high Ground clearance Dead weight without fuel Max. permissible front axle load Max. permissible rear axle load Max. permissible laden weight spring type . . . . . . . . . . . . . . . . . . . . . . . 70 - 260 Disc brake with carbon-steel brake disc Ø 320 mm (12,6 in) and 4-piston brake caliper Disc brake with carbon-steel brake disc Ø 220 mm (8,7 in) and single-piston brake caliper floated front: 120/70 R 17 58H rear: 160/60 R 17 69H 2.0 bar (29 psi) 2.2 bar (32 psi) 2.2 bar (32 psi) 2.4 bar (35 psi) 11 liter (2,9 US gallons), out of this 2,5 liter (0,6 US gallons) reserve 17 : 38 X-ring 5/8 x 1/4" low beam . . . . . . . . . . . . . . . . . . . . . . . . HB3 12V 65W (socket P20d) high beam . . . . . . . . . . . . . . . . . . . . . . . HB3 12V 65W (socket P20d) parking light . . . . . . . . . . . . . . . . . . . . . . 12V 5W (socket W2,1x9,5d) speedometer, tachometer light . . . . . . . . . 12V 1,2W (socket W2x4,6d) indicator lamp . . . . . . . . . . . . . . . . . . . . . 12V 1,2W (socket W2x4,6d) stop and taillight . . . . . . . . . . . . . . . . . . . 12V 21/5W (socket BaY15d) flasher . . . . . . . . . . . . . . . . . . . . . . . . . . 12V 10W (socket Ba15s) maintenance-free battery 12V 8Ah 64,2° 1460 ± 15 mm (57.5 ± 0.6 in) 880 mm (34,7 in) 250 mm (9.9 in) 145 kg (3 lbs) 150 kg (2 lbs) 200 kg (4 lbs) 350 kg (773 lbs) 10-62D TECHNICAL SPECIFICATIONS – ENGINE 625 SXC 2003 Engine Design Displacement Bore / Stroke Ratio Fuel Valve timing Camshaft Valve diameter Valve clearence cold Crank shaft bearing Connecting rod bearing Top end bearing Piston Piston rings Engine lubrication Engine oil Engine oil quantity Primary ratio Clutch Transmission Gear ratio Ignition system Ignition timing Generator Spark plug Spark plug gap Cooling system Cooling liquid Starting equipment 625 SXC Liquid-cooled single cylinder 4-stroke engine with balancer shaft 625 ccm 101 / 78 mm 11,5 : 1 unleaded premium gasoline with a least RON 95 4 valves over rocker arm and 1 overhead camshaft, camshaft drive through single chain 584-V03/1 Intake: 36 mm Exhaust: 32 mm Intake: 0,15 mm Exhaust: 0,15 mm 2 cylinder roller bearing needle bearing bronze bushing forged aluminium alloy 1 compression ring, 1 taper face ring, 1 oil scraper ring two Eaton-oilpumps SAE 5W/40, 10W-50 (f.ex. Motorex Power Synt 4T) 1,6 liters (0,42 US gallons) straight geared spur wheels 31 : 79 teeth multi disc clutch in oil bath 5-speed claw shifted 1st 14:35 2nd 15:24 3rd 18:21 4th 20:19 5th 22:18 contactless DC-CDI ignition with digital advanced system type KOKUSAN adjustment to max. 38 ° BTDC at 6000 rpm 12V 200W NGK DCPR8 E 0,9 mm liquid cooled, permanent rotation of cooling liquid through mechanic driven water pump 1 liter, 40% antifreeze, 60% water, at least –25°C (–13°F) kick - electric starter BASIC CARBURETOR SETTING BASIC CARBURATOR SETTING 625 SXC USA 625 SXC Type Carburator-setting number Main jet Jet needle Idling jet Main air jet Idling air jet Needle position Starting jet Mixture control screw open Slide Performance restrictor Stop pump membrane Hot start device Keihin FCR-MX 41 4138A 165 OBDVT 42 200 100 5. rd from top 85 2 15 Slide stop 858 / 2,15 mm 3,8 mm Type Main jet Needle jet Idling jet Jet needle Needle clip pos. f. top Mixt. adj. screw open Mikuni BST40-266 152,5 X-6 689 45 6G5 3. from top 2,25 10-63D TECHNICAL SPECIFICATIONS - CHASSIS 625 SXC 2003 Art.-Nr. 3.206.006 -E Frame Fork Wheel travel front/rear Rear suspension Front brake Front brake disc Rear brake Tyres front Air press. offroad Air press. road Tyres rear Air press offroad Air press. road Fuel tank capacity Final drive ratio Chain Bulps Battery Steering angle Wheel base Seat high Ground clearance Dead weight without fuel 625 SXC Central chrome-moly-steel frame White Power 4357 MXMA 295 / 320 mm (11,8 / 12,8 in) Central shock absorber (WP BAVP4681) with PRO-LEVER linkage to rear- swing-arm with needle bearing Disc brake with carbon-steel brake disc, brake caliper floated Ø 260 mm (10,4 in) Disc brake with carbon-steel brake disc 220 mm (8.8 in), brake caliper floated 90/90-21 1,0 bar (14 psi) 1,8 bar (26 psi) 140/80-18 1,2 bar (17 psi) 2,0 bar (29 psi) 9 liter (2,3 US gallons), 2.5 liter (0,6 US gallons) reserve 16:40 ( USA 15:50) t X – Ring 5/8 x 1/4" headlight . . . . . . . . . . . . . HS1 12V 35/35W (socket PX43t) parking light . . . . . . . . . . . 12V 5W (socket W2,1x9,5d) indicator lamps . . . . . . . . . 12V 1,2W (socket W2x4,6d) brake – rear light . . . . . . . 12V 21/5 W (socket BaY15d) flasher light . . . . . . . . . . . 12V 10W (socket Ba15s) license plate illmination . . . 12V 5W (socket W2,1x9,5 d) maintenance-free battery 12V 8,6 Ah 62,5 ° 1510 ± 10 mm (59.4 ± 0.4 in) 980 mm (39,2 in) 360 mm (14,4 in) 132 kg (291 lbs) Repair manual KTM LC4 STANDARD ADJUSTMENT - FORK Compression adjuster Rebound adjuster Spring Spring preload Air chamber length Fork oil 625 SXC WP 0518X729 20 12 4,2 N/mm 5 mm 140 mm SAE 5 STANDARD-ADJUSTMENT-SHOCK ABSORBER Compression adjuster Rebound adjuster Spring Spring preload 625 SXC WP 0118X725 3 5 63 / 260 23 mm 10-64D TECHNICAL DATA – ENGINE 640 LC4, 640 LC4 Supermoto Engine Design Displacement Bore / Stroke Ratio Fuel Valve timing Camshaft Valve diameter Valve clearence cold Crank shaft bearing Connecting rod bearing Top end bearing Piston Piston rings Engine lubrication Engine oil Engine oil quantity Primary ratio Clutch Transmission Gear ratio Ignition system Ignition timing Generator Spark plug Spark plug gap Cooling system Cooling liquid Starting equipment 640 LC4 Liquid-cooled single cylinder 4-stroke engine with balancer shaft and electric starter 625 ccm 101 / 78 mm 11.5 : 1 unleaded premium gasoline with a least RON 95 4 valves over rocker arm and 1 overhead camshaft, camshaft drive through single chain 584-V03/1 Intake: 36 mm Exhaust: 32 mm 0,15 mm Exhaust: 0,15 mm 2 cylinder roller bearing needle bearing bronze bushing forged/cast aluminium alloy 1 compression ring, 1 taper face ring, 1 oil scraper ring two Eaton-oilpumps SAE 5W/40, 10W-50 (f.ex. Motorex Power Synt 4T) appr. 2,1 liters including frame straight geared spur wheels 31 : 79 teeth multi disc clutch in oil bath, hydraulically operated 5-speed claw shifted 1st 14:35 2nd 15:24 3rd 18:21 4th 20:19 5th 22:18 contactless DC-CDI ignition with digital advanced system type KOKUSAN 4K5 adjustment to max. 38° BTDC at 6000 rpm 12V 200W NGK DCPR 8 E 0,9 mm liquid cooled, permanent rotation of cooling liquid through mechanic driven water pump 1 liter, 40% antifreeze, 60% water, at least –25 ° C (–13 ° F) electric starter and kickstarter BASIC CARBURETOR SETTING BASIC CARBURETOR SETTING 640 LC4 640 LC4 Supermoto Type Main jet Needle jet Idling jet Jet needle Needle clip pos. f. top Mixt. adj. screw open BST40-266 152,5 X-6 689 45 6G5 3. from top 2,25 BASIC CARBURETOR SETTING 640 DUKE 40 kW Carburetor Main jet Needle jet Idling jet Jet needle Needle position from top Mixture.adju. screw open 2003 BST40-258 145 689 X-6 45 6G5 3 rd 2.25 turn 640 LC4 Adventure Type Main jet Needle jet Idling jet Jet needle Needle clip pos. f. top Mixt. adj. screw open BST40-266 152,5 X-6 689 45 6G5 3. from top 2,25 10-65D TECHNICAL SPECIFICATIONS - CHASSIS 640 LC4, 640 LC4 SUPERMOTO 2003 Art.-Nr. 3.206.006 -E 640 LC4 640 LC4 Supermoto Frame Central chrome-moly-steel frame Fork White Power – Up Side Down 4357 MXMA White Power – Up Side Down 4860 MXMA Wheel travel front/rear 270 / 300 mm (10,6 / 11.8 in) 265 / 310 mm (10,4 / 12,2 in) Rear suspension Central shock absorber (WP BAVP3612) with PRO-LEVER linkage to rear- swing-arm with needle bearing Front brake Disc brake with carbon-steel brake disc, Disc brake with carbon-steel brake disc, 2-piston brake caliper floated 4-piston brake caliper Front brake disc Ø 300 mm (11.8 in) Ø 320 mm (12.6 in) Rear brake Disc brake with carbon-steel brake disc 220 mm (8.7 in), brake caliper floated Tyres front 90/90-21 120/70-17 Air press. road, driver only 1.8 bar (26 psi) 2.0 bar (29 psi) Air press. road with passenger 2.0 bar (29 psi) 2.2 bar (31 psi) Tyres rear 130/80-18 160/60-17 Air press. road, driver only 2.0 bar (29 psi) 2.2 bar (31 psi) Air press. road with passenger 2.2 bar (31 psi) 2.4 bar (34 psi) Fuel tank capacity 11 liter (2.9 US gallons), 2.5 liter (0.6 US gallons) reserve Final drive ratio 16:42t 17:42t Chain X – Ring 5/8 x 1/4" Bulps headlight . . . . . . . . . . . . . H4 12V 60/55W (socket P43t) parking light . . . . . . . . . . . 12V 5W (socket W2,1x9,5d) instrument lights . . . . . . . . 12V 1,2W (socket W2x4,6d) indicator lamps . . . . . . . . . 12V 1,2W (socket W2x4,6d) brake – rear light . . . . . . . 12V 21/5 W (socket BaY15d) flasher light . . . . . . . . . . . 12V 10W (socket Ba15s) license plate illmination . . . 12V 5W (socket W2,1x9,5 d) Battery maintenance-free battery 12V 8,6Ah Steering angle 62° 63° Wheel base 1510 ± 10 mm (59.4 ± 0.4 in) Seat high 925 mm (36.4 in) 910 mm (35.9 in) Ground clearance 310 mm (12.2 in) 290 mm (11.4 in) Dead weight without fuel 149kg (329 lbs) 149 kg (329 Ibs) Max. permissible front axle load 150 kg (331 lbs) Max. permissible rear axle load 230 kg (508 lbs) Max. permissible laden weight 350 kg (773 lbs) STANDARD ADJUSTMENT - FORK Repair manual KTM LC4 640 LC4 Compression adjuster Rebound adjuster Spring Spring preload Air chamber length Fork oil WP 0518X730 20 12 4,2 N/mm 6 mm (0.24in) 150 mm (5,9in) SAE 5 STANDARD-ADJUSTMENT - SHOCK ABSORBER 640 LC4 SUPERMOTO WP 0518X738 20 15 4,4 N/mm 28 mm (1.1in) 110 mm (4.3in) SAE 5 640 LC4 Compression adjuster Rebound adjuster Spring Spring preload WP 0118X729 3 7 66 / 260 23,5 mm(0,93in) 640 LC4 SUPERMOTO WP 0118X730 4 8 70 / 260 16 mm(0,63in) 10-66D TECHNICAL SPECIFICATIONS - CHASSIS 640 LC4 ADVENTURE 2003 640 LC4 Adventure Frame Central chrome-moly-steel frame Fork WP USD MXMA 4860 Wheel travel front/rear Rear suspension 275/300 mm (10,5/12 in) Central shock absorber (WP BAVP3612) with PRO-LEVER linkage to rear-swingarm with needle bearing Front brake Disc brake with carbon-steel brake disc Ø 320 mm (11,8 in), brake caliper floated Rear brake Disc brake with carbon-steel brake disc Ø 220 mm (8,7 in), brake caliper floated Tyres front 90/90-21 Enduro3 Air pressure offroad 1,8 bar (21 psi) Air press. road, driver only 2,0 bar (29 psi) Tyres rear 140/80-18 Enduro3 Air press. road, driver only 2,0 bar (29 psi) Air press. road, with passenger 2,2 bar (32 psi) Fuel tank capacity 28 liter (7,4 US gallons) of that 3,5 liter (0,9 US gallons) reserve Final drive ratio 16 : 42 Chain 5/8 x 1/4 "X-Ring Bulbs head light . . . . . . . . . . . . . . . . . . . . . .H1 12V 55W (Sockel P14,5S) parking light . . . . . . . . . . . . . . . . . . . .12V 2W (Sockel Ba9s) brake- rear light . . . . . . . . . . . . . . . . .12V 21/5W (Sockel BaY15d) flasher light . . . . . . . . . . . . . . . . . . . . .12V 10W (Sockel Ba15s) license plate illintion . . . . . . . . . . . . . .12V 5W (Sockel W2,1x9,5d) Battery maintenance-free battery Steering angle 62,5° Wheel base 1510 ± 10 mm (59,4 ± 0,4 in) Seat high 945 mm (37,2 in) Ground clearance 315 mm (12,4 in) Dead weight without fuel 158 kg (340 lbs) Max. permissible front axle load 150 kg (331 lbs) Max. permissible rear axle load 230 kg (507 lbs) Max. permissible laden weight 380 kg (839 lbs) STANDARD ADJUSTMENT - FORK Compression adjuster Rebound adjuster Spring Spring preload Air chamber length Capacity per fork leg Fork oil 12V 8Ah WP 4860 MXMA 1418X728 14 14 4,4 N/mm 4 mm 120 mm ca 420 ccm SAE 5 STANDARD-ADJUSTMENT - SHOCK ABSORBER Compression adjuster Rebound adjuster Spring Spring preload WP BAVP3612 0118X726 6 7 70/260 27 mm (0,9 in) 10-67D TECHNICAL SPECIFICATIONS - CHASSIS Frame Fork Rear suspension Shock absorber Repair manual KTM LC4 Art.-Nr. 3.206.006 -E Front brake Rear brake Tyres Air pressure rider only Air pressure with passenger Fuel tank capacity Final drive ratio Chain Lamps Battery Steering angle Wheel base Seat high Ground clearance Dead weight without fuel Max. permissible front axle load Max. permissible rear axle load Max. permissible laden weight 640 DUKE II 2003 Central chrome-moly-steel frame type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP 4357 ROMA 0518X732 wheel travel . . . . . . . . . . . . . . . . . . . . . . . . . . . 140 mm (5.5 in) standard adjustment compression . . . . . . . . . . . driver only = 14, with passenger = 14 standard adjustment rebound . . . . . . . . . . . . . . driver only = 16, with passenger = 16 fork leg projection upper fork bridge . . . . . . . . . 3 mm (0.12 in) oil capacity per fork leg . . . . . . . . . . . . . . . . . . . appr. 400 ccm (24 cubic in) / SAE 5 air chamber lenght . . . . . . . . . . . . . . . . . . . . . . 100 mm (4 in) WP central shock absorber with PRO-LEVER linkage to rear- swing-arm with needle bearing type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WP central shock absorber BAVP 4681 0118X728 rear wheel travel . . . . . . . . . . . . . . . . . . . . . . . . 170 mm (6.7 in) standard adjustment compression . . . . . . . . . . . driver only = 3, with passenger = 5 standard adjustment rebound . . . . . . . . . . . . . . driver only = 5, with passenger = 3 spring preload . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . driver only = 23 mm (0.9 in),with passenger = 28 mm (1.1 in) spring type . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 - 260 Disc brake with carbon-steel floated brake disc Ø 320 mm (12.6 in) and 4-piston brake caliper Disc brake with carbon-steel brake disc Ø 220 mm (8.7 in) and single-piston brake caliper floated front: 120/70 R 17 58H rear: 160/60 R 17 69H 2.0 bar (29 psi) 2.2 bar (32 psi) 2.2 bar (32 psi) 2.4 bar (35 psi) 11 liters (2.9 US gallons), out of this 2.5 liters (0.6 US gallons) reserve 16 : 38 X-ring 5/8 x 1/4" low beam . . . . . . . . . . . . . . . . . . . . . . . . HB3 12V 65W (socket P20d) high beam . . . . . . . . . . . . . . . . . . . . . . . HB3 12V 65W (socket P20d) parking light . . . . . . . . . . . . . . . . . . . . . . 12V 5W (socket W2,1x9,5d) speedometer, tachometer light . . . . . . . . . 12V 1,2W (socket W2x4,6d) indicator lamp . . . . . . . . . . . . . . . . . . . . . 12V 1,2W (socket W2x4,6d) stop and taillight . . . . . . . . . . . . . . . . . . . 12V 21/5W (socket BaY15d) flasher . . . . . . . . . . . . . . . . . . . . . . . . . . 12V 10W (socket Ba15s) maintenance-free battery 12V 8Ah 63.5° 1460 ± 15 mm (57.5 ± 0.6 in) 900 mm (35.5 in) 270 mm (10.6 in) 149 kg (329 lbs) 150 kg (331 lbs) 200 kg (441 lbs) 350 kg (773 lbs) 10-68D TECHNICAL SPECIFICATIONS – ENGINE 660 SMC 2003 Engine Design Displacement Bore / Stroke Ratio Fuel Valve timing Camshaft Valve diameter Valve clearence cold Crank shaft bearing Connecting rod bearing Top end bearing Piston Piston rings Engine lubrication Engine oil Engine oil quantity Primary ratio Clutch Transmission Gear ratio Ignition system Ignition timing Generator Spark plug Spark plug gap Cooling system Cooling liquid Starting equipment 660 SMC Liquid-cooled single cylinder 4-stroke engine with balancer shaft 653 ccm 102 / 80 mm 11,5 : 1 unleaded premium gasoline with a least RON 95 4 valves over rocker arm and 1 overhead camshaft, camshaft drive through single chain 586-V039 Intake: 36 mm Exhaust: 32 mm Intake: 0,15 mm Exhaust: 0,15 mm 2 cylinder roller bearing needle bearing bronze bushing forged aluminium alloy 1 compression ring, 1 taper face ring, 1 oil scraper ring two Eaton-oilpumps SAE 5W/40, 10W-50 (f.ex. Motorex Power Synt 4T) 1,6 liters (0,42 US gallons) straight geared spur wheels 31 : 79 teeth multi disc clutch in oil bath 5-speed claw shifted 1st 14:35 2nd 15:24 3rd 18:21 4th 20:19 5th 22:18 contactless DC-CDI ignition with digital advanced system type KOKUSAN adjustment to max. 38 ° BTDC at 6000 rpm 12V 200W NGK DCPR8 E 0,9 mm liquid cooled, permanent rotation of cooling liquid through mechanic driven water pump at least –25°C (–13°F) kickstarter BASIC CARBURATOR SETTING 660 SMC Type Carburator-setting number Main jet Jet needle Idling jet Main air jet Idling air jet Needle position Starting jet Mixture control screw open Slide Performance restrictor Stop pump membrane Hot start device Keihin FCR-MX 41 4138A 165 OBDVT 42 200 100 5. rd from top 85 2 15 Slide stop 858 / 2,15 mm 3,8 mm 10-69D TECHNICAL SPECIFICATIONS - CHASSIS 660 SMC 2003 Art.-Nr. 3.206.006 -E Frame Fork Wheel travel front/rear Rear suspension Front brake Front brake disc Rear brake Tyres front Air press. Tyres rear Air press. Fuel tank capacity Final drive ratio Chain Bulps Steering angle Wheel base Seat high Ground clearance Dead weight without fuel 660 SMC Central chrome-moly-steel frame White Power 4860 MXMA 265 / 310 mm (10,6 / 12,4 in) Central shock absorber (WP BAVP4681) with PRO-LEVER linkage to rear- swing-arm with needle bearing Disc brake with carbon-steel brake disc, and 4 piston brake caliper Ø 320 mm (12,8 in) Disc brake with carbon-steel brake disc 220 mm (8.8 in), brake caliper floated 120/70-17 2 bar (29 psi) 160/60-17 2,2 bar (31 psi) 9 liter (2,3 US gallons), 2.5 liter (0,6 US gallons) reserve 16:38 X – Ring 5/8 x 1/4" headlight . . . . . . . . . . . . . HS1 12V 35/35W (socket PX43t) parking light . . . . . . . . . . . 12V 5W (socket W2,1x9,5d) indicator lamps . . . . . . . . . 12V 1,2W (socket W2x4,6d) brake – rear light . . . . . . . 12V 21/5 W (socket BaY15d) flasher light . . . . . . . . . . . 12V 10W (socket Ba15s) license plate illmination . . . 12V 5W (socket W2,1x9,5 d) 63 ° 1510 ± 10 mm (59.4 ± 0.4 in) 910 mm (36,4 in) 290 mm (11,6 in) 131 kg (289 lbs) Repair manual KTM LC4 STANDARD ADJUSTMENT - FORK Compression adjuster Rebound adjuster Spring Spring preload Air chamber length Fork oil 660 SMC WP 1418X738 20 15 4,4 N/mm 28 mm 110 mm SAE 5 STANDARD-ADJUSTMENT-SHOCK ABSORBER Compression adjuster Rebound adjuster Spring Spring preload 660 SMC WP 0118X730 4 8 70 / 260 22 mm 10-70D TIGHTENING TORQUE - ENGINE Hexagon nut at primary gear Collar nut flywheel (LC4, ADVENTURE, DUKE) Collar nut flywheel (SC, SXC) Hexagon nut for inner clutch hub Collar bolt clutch springs Kickstarter stop bolt Allen head bolt freewheel hub (E-STARTER) Allen head bolts oil pumps Collar bolts oil pumps (from modell 2003 on) Hexagon bolt camshaft gear Allen head bolts cylinder head top section Allen head bolts cylinder head top section Bolts cylinder head top section (from model 2003 on) Bolts cylinder head top section (from model 2003 on) Cylinder head to cylinder Cylinder head to cylinder Cylinder head to cylinder (from model 2003 on) Cylinder head bolts Collar nuts at cylinder base Plug at cylinder head (SC) Hexagon bolt chain sprocket 8.8 Hexagon bolt chain sprocket 12.9 Nut chain sprocket Oil drain plug Magnetic plug Plug bypass valve Banjo bolts oil lines Banjo bolts oil lines Jet screw clutch cover Plug timing-chain tensioner Timing-chain tensioner to cylinder Timing-chain tensioner to cylinder (from model 2003 on) Timing-chain guide to cylinder Hexagon bolt timing-chain guide Tension guide Timing-chain securing guide Allen head bolt timing-chain securing guide (from model 2003 on) Counternuts valve adjusting screws Crankshaft locking bolt Spark plug Engine mounting bolt Engine mounting bolt Retaining plate for main shaft bearing Retaining plate for main shaft bearing (from model 2003 on) Shift mechanism support, securing device for bearing Shift mechanism support Shift mechanism support (from model 2003 on) Shift drum locating Engine housing, clutch cover, ignition cover Water pump cover Bolts of impuls generator Stator (SC) Stator (E-Start) Kick starter Shifting lever Oil filter cover Microfilter cover (SC) Starter flange, starter cover AH bolt for slave cylinder Starter Valve cover Exhaust flange AH screw for decompression shaft lever Retaining shim for ignition (SC) Other bolts, engine M20x1,5 Loctite 243 + 170 Nm M16x1,25 links 80° C + 150 Nm M12x1 left 60 Nm M18x1,5 Loctite 243 + 100 Nm M6 10 Nm M12x1,5 50 Nm M6x12/M6x12,5 Loctite 648 + 12/16 Nm M6 Loctite 243 + 8 Nm M6 Loctite 243 + 10 Nm M10 Loctite 243 + 35 Nm M6x25/M6x35/M6x65/M6x70 (8.8) 8 Nm M6x50/M6x55 (12.9) 15 Nm M6 (8.8) 10 Nm M7 (12.9) 15 Nm M8 25 Nm M6 8 Nm M6 10 Nm M10 50 Nm M10 40 Nm M10 20 Nm M10 Loctite 243 + 40 Nm M10 Loctite 243 + 60 Nm M20x1,5 60 Nm M22x1,5 30 Nm M12x1,5 20 Nm M12x1,5 20 Nm M8x1 10 Nm M10x1 15 Nm M8 10 Nm M12x1,5 20 Nm M6 Loctite 243 + 8 Nm M6 10 Nm M12x1,25 Loctite 243 + 8 Nm M6 Loctite 243 + 10 Nm M8 Loctite 243 + 15 Nm M6 8 Nm M6 Loctite 243 + 10 Nm M7x0,75 16 Nm M8 25 Nm M12x1,25 20 Nm M8 40 Nm M10 70 Nm M6 Loctite 648 + 8 Nm M6 Loctite 648 + 10 Nm M5 Loctite 243 + 6 Nm M6 Loctite 243 + 8 Nm M6 Loctite 243 + 10 Nm M6 Loctite 243 + 8 Nm M6 10 Nm M6 10 Nm M5 Loctite 243 + 6 Nm M6 Loctite 243 + 8 Nm M5 Loctite 243 + 6 Nm M8 25 Nm M6 Loctite 243 + 10 Nm M6 10 Nm M5 6 Nm M6 10 Nm M6 10 Nm M6 10 Nm M6 10 Nm M6 10 Nm M6 Loctite 243 + 10 Nm M5 Loctite 243 + 6 Nm M5 6 Nm M6 10 Nm 10-71D TIGHTENING TORQUE - CHASSIS Art.-Nr. 3.206.006 -E Collar nut front axle M16x1,5, M17 40 Nm Collar nut front axle (400 SXC) M10 40 Nm Collar nut front axle M24x1,5 40 Nm Collar nut rear axle M20x1,5 80 Nm Shock absorber top M10 45 Nm Shock absorber bottom M10 Collar bolts brake disk front M6 Loctite 243 + 10 Nm Collar bolts brake disk front M6 Loctite 243 + 10 Nm Bolts brake caliper front M8 Loctite 243 + 25 Nm 45 Nm Bolts brake caliper front (LC4 Supermoto) M10 Loctite 243 + 40 Nm Allen head bolts brake caliper front (DUKE) M10x1,25 Loctite 243 + 45 Nm Allen head bolt brake caliper support rear (DUKE) M10 40 Nm Allen head bolts brake caliper front (660 SMC) M10 60 Nm Bearing bolt linkage arm/frame M12 Collar nuts rocker arm bolts M14x1,5 Engine mounting bolt M10 Ball joint for push rod M8 Loctite 243 + 25 Nm Sprocket bolts with nuts M8 Loctite 243 + 35 Nm Collar nut swingarm bolt M14x1,5 60 Nm 100 Nm 45 Nm 100 Nm Clamping bolts top triple clamp (USD 43) M8 20 Nm Clamping bolts top triple clamp (EXTREME) M8 15 Nm Clamping bolts top triple clamp (USD 48) M8 20 Nm Clamping bolts bottom triple clamp (USD 43) M8 15 Nm Clamping bolts bottom triple clamp (EXTREME) M8 20 Nm Clamping bolts bottom triple clamp (USD 48) M8 15 Nm Clamp bolts for front wheel axle clamp M8 10 Nm Collar nut for eccentric chain adjuster (DUKE) M10 40 Nm Bolts, handlebar clamp M8 Loctite 243 + 20 Nm Allen head bolts handle bar support, damped M10 Loctite 243 + 20 Nm Allen head bolts handle bar support, not damped (SC, SC-SM, SXC) M10 Loctite 243 + 40 Nm Rim lock M8 5 Nm Clamping of steering stemm M8 20 Nm Subframe M8 Loctite 243 + 35 Nm Spoke nipple M4 4 Nm Repair manual KTM LC4 (LC4, LC4-SM, SMC, ADVENTURE, DUKE) Blocking bolt of adjusting ring for spring preload M6 8 Nm Other bolts on chassis M6 10 Nm M8 25 Nm M10 45 Nm Other collar nuts on chassis M6 15 Nm M8 30 Nm M10 50 Nm 10-72D ASSEMBLY CLEARANCE, WEAR LIMIT Crank shaft Connecting rod bearing Cylinder 400 Cylinder 640 Cylinder 660 Piston forged Piston cast Piston rings end gap Valves Oil pumps Bypaß valve Clutch Camshaft Transmission shafts Crankshaft webs – outer dimension axial play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.03 - 0.12 mm run out of crank stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .max. 0.08 mm radial play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .max. 0.05 mm axial play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .max. 1.10 mm bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .max. 89.04 mm bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .max. 101.04 mm bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . max. 102.04 mm assembly clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .max. 0.12 mm assembly clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .max. 0.05 mm compression rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .max. 0.80 mm oil scraper ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .max. 1.00 mm seat sealing intake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .max. 1.50 mm seat sealing exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .max. 2.00 mm run out of valve heads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .max. 0.05 mm valve guides diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .max. 7.05 mm clearance outer rotor - housing . . . . . . . . . . . . . . . . . . . . . . . . . .max. 0.20 mm clearance outer rotor - inner rotor . . . . . . . . . . . . . . . . . . . . . . . .max. 0.20 mm minimum spring length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25.00 mm Length of springs . . . . . . . . . . . . . . . . . . . . . . .min. 34.5 mm (new 37.00 mm) wear limit organic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .min. 2.50 mm Length of the clutch spring 660 SMC . . . . . . . . . . min. 31.5 mm (new 33.5 mm) diameter of bearing bolt (needle bearing) . . . . . . . . . . . . . . . . . .min. 19.97 mm axial play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.10 - 0.40 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .66 mm +/- 0.05 mm 11-1D PERIODIC MAINTENANCE SCHEDULE Art.-Nr. 321030-E INDEX MODEL 1998 PERIODIC MAINTENANCE PERIODIC MAINTENANCE PERIODIC MAINTENANCE PERIODIC MAINTENANCE SCHEDULE SCHEDULE SCHEDULE SCHEDULE SX, SXC, SC . . . . . . . . . . LC4 COMPETITION, LC4 ADVENTURE-R . . . . . . . DUKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-2 .11-3 .11-4 .11-5 MODEL1999 PERIODIC MAINTENANCE PERIODIC MAINTENANCE PERIODIC MAINTENANCE PERIODIC MAINTENANCE SCHEDULE SCHEDULE SCHEDULE SCHEDULE SX, SXC, SC . . . . . . . . . . LC4 COMPETITION, LC4 ADVENTURE-R . . . . . . . DUKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-6 .11-7 .11-8 .11-9 MODEL 2001 PERIODIC MAINTENANCE SCHEDULE 620 SC . . . . . . . . . . . . . . . . . .11-10 PERIODIC MAINTENANCE SCHEDULE LC4-E, ADVENTURE . . . . . . . .11-12 PERIODIC MAINTENANCE SCHEDULE DUKE . . . . . . . . . . . . . . . . . . .11-14 Repair manual KTM LC4 MODEL 2002 PERIODIC MAINTENANCE SCHEDULE 625 SC . . . . . . . . . . . . . . . . . .11-16 PERIODIC MAINTENANCE SCHEDULE LC4, ADVENTURE . . . . . . . . . .11-18 PERIODIC MAINTENANCE SCHEDULE DUKE . . . . . . . . . . . . . . . . . . .11-20 MODEL 2003 PERIODIC MAINTENANCE SCHEDULE 625 SXC, 660 SMC . . . . . . . . .11-22 PERIODIC MAINTENANCE SCHEDULE 640 LC4, 640 LC4 ADVENTURE . . .11-24 PERIODIC MAINTENANCE SCHEDULE DUKE . . . . . . . . . . . . . . . . . . .11-26 11 11-2D Art.-Nr. 3.206.006 -E Check engine oil level Change engine oil Clean oil screen and magnet of the drain plugs whenever you exchange the engine oil Change oil filter unit Change microfilter Check oil lines for leakage and proper instalment Check valve clearance Clean spark plug and adjust electrode gap Change spark plug after 10 000 kilometers (6 200 miles) Check valve clearance Drain and clean carburator float bowl Adjust idling Check breather hoses of engine gase and gas tank for correct position without buckles Clean air filter and air filter box Check sprockets, chain guides and chain for wear Clean and lube chain Check chain tension Check cooling liquid level Check quality of antifreeze Check cooling system for leaks Check exhaust system for leakage Change exhaust muffler packing Check exhaust brackets Disassemble and clean spark arrestor discs (USA models) Check brake fluid level front and rear Change brake fluid Check brake pad thickness Check brake discs Check condition and correct instalment of brake hoses Check freeplay and easy operation of hand brake lever and foot brake lever Check adjustment and function of fork Check fork for leaks Perform a full maintenance job for the telescopic fork Servicing the shock absorber Grease lubricating nipple of the Pro Lever suspension system Disassemble the Pro Lever suspension system and perform a full maintenance job on it Spray ignition lock, short circuit button, and light switch with contact spray Check all bolts, nuts and hose clamps for proper tightness Grease or lube all pivot points and sliding components Check O-ring of the shock absorber for wear Servicing swingarm pivots Check tightness of spokes and rim join Check wheel bearings for clearance Check chock absorber rubbers on the rear wheel hub Check tire condition and air pressure Check cables for damage and easy working Lube and adjust cables Check the electrical system Check adjustment of head light Change fork oil Clean dust scrabber on forks Check steering head bearing clearance / adjust Clean and grease steering head bearings and its seals Check adjustment and funktion of shock absorber Loosen breather screws at fork legs (overpressure) Repair manual KTM LC4 at least once a year after 5000 km (3000 miles) or once a year 1st service, after 1000 km (600 miles) or 10 hours after 2500 km (1500 miles) or 25 hours IF THE MOTORCYCLE IS USED PRIMARILI FOR OFF ROAD RIDING OR COMPETITIVE RACING, THE 5000 KM (3000 MILES) SERVICE NEEDS TO BE CARRIED OUT AFTER EACH RIDE OR RACE KTM dealer after washing SX, SXC, SC 9.97 KTM rider before each start PERIODIC MAINTENANCE SCHEDULE 11-3D KTM rider PERIODIC MAINTENANCE SCHEDULE after 5000 km (3000 miles) or once a year at least once a year Clean oil screen and magnet of the drain plugs whenever you exchange the engine oil Change oil filter insert Change fine screen filter (screwed filter) at front pipe (of the frame) Check oil lines for leakage and proper instalment without kinks Check valve clearance Check engine oil level after washing Change engine oil IF THE MOTORCYCLE IS USED PRIMARILI FOR OFF ROAD RIDING OR COMPETITIVE RACING, THE 5000 KM (3000 MILES) SERVICE NEEDS TO BE CARRIED OUT AFTER EACH RIDE OR RACE before each start 1st service, after 500 km (300 miles) 400/640 LC4’98 620 LC4 Comp.’98 4. 98 KTM dealer Clean spark plug and adjust electrode gap Change spark plug after 10 000 kilometers (6 200 miles) Drain and clean carburetor float chamber Check all air supply and ventilation hoses of of the engine and of the carburetor for kinks Clean air filter and air filter box Check sprockets, chain guides and chain for wear Clean and lube chain Check chain tension Check cooling liquid level Check exhaust system for leakage Check exhaust brackets Disassemble and clean spark arrestor discs (USA models) Check brake fluid level front and rear Change brake fluid Check brake pad thickness Check brake discs Check condition and correct instalment of brake hoses Check free play and easy operation of foot brake pedal Check adjustment and function of telescopic fork Check telescopic fork for leaks Loosen bleeder screws at fork legs (overpressure) Change telescopic fork oil Perform a full maintenance job for the telescopic fork Clean dust scrabber of telescopic fork Check steering head bearing clearance / adjust Clean and grease steering head bearings and its seals Check adjustment and funktion of shock absorber Check quality of antifreezer Check cooling system for leaks – visual check Adjust idling Check O-ring of the shock absorber for wear Service the shock absorber Grease nipple of the Pro Lever suspension system Disassemble the Pro Lever suspension system linkage and perform a full maintenance job on it Service swingarm pivot Check spoke tension and join Check wheel bearings for clearance Check shock absorber rubbers on the rear hub Check tire condition and air pressure Check cables for damage and easy working Lube and adjust cables Check the electrical system Check battery holder, battery and connections Check adjustment of headlight Spray ignition lock, emergency off switch, and light switch with contact spray Check all bolts, nuts and hose clamps for proper tightness Grease or lube all pivot points and sliding points 11-4D Repair manual KTM LC4 Art.-Nr. 3.206.006 -E Check engine oil level Change engine oil Clean oil screen and magnet of the drain plugs whenever you exchange the engine oil Change oil filter insert Change fine screen filter (screwed filter) at front pipe (of the frame) Check oil lines for leakage and proper instalment without kinks Check valve clearance Clean spark plug and adjust electrode gap Change spark plug after 10 000 kilometers (6 200 miles) Check ignition point Drain and clean carburetor float chamber Adjust idling Check breather hoses of engine gase and gas tank for correct position without buckles Clean air filter and air filter box Check sprockets, chain guides and chain for wear Clean and lube chain Check chain tension Check cooling liquid level Check quality of antifreezer Check cooling system for leaks – visual check Check exhaust system for leakage Check exhaust brackets Disassemble and clean spark arrestor discs (USA models) Check brake fluid level front and rear Change brake fluid Check brake pad thickness Check brake discs Check condition and correct instalment of brake hoses Check free play and easy operation of foot brake pedal Check adjustment and function of telescopic fork Check telescopic fork for leaks Loosen bleeder screws at fork legs (overpressure) Change telescopic fork oil Perform a full maintenance job for the telescopic fork Clean dust scrabber of telescopic fork Check steering head bearing clearance / adjust Clean and grease steering head bearings and its seals Check adjustment and funktion of shock absorber Check O-ring of the shock absorber for wear Service the shock absorber Grease nipple of the Pro Lever suspension system Disassemble the Pro Lever suspension system linkage and perform a full maintenance job on it Service swingarm pivot Check spoke tension and join Check wheel bearings for clearance Check shock absorber rubbers on the rear hub Check tire condition and air pressure Check cables for damage and easy working Lube and adjust cables Check the electrical system Check battery holder, battery and connections Check adjustment of headlight Spray ignition lock, emergency off switch, and light switch with contact spray Check all bolts, nuts and hose clamps for proper tightness Grease or lube all pivot points and sliding points at least once a year after washing IF THE MOTORCYCLE IS USED PRIMARILI FOR OFF ROAD RIDING OR COMPETITIVE RACING, THE 5000 KM (3000 MILES) SERVICE NEEDS TO BE CARRIED OUT AFTER EACH RIDE OR RACE before each start Adventure-R 3.98 after 5000 km (3000 miles) or once a year KTM dealer after 2500 km (1500 miles) KTM rider 1st service, after 500 km (300 miles) PERIODIC MAINTENANCE SCHEDULE 11-5D Check engine oil level Change engine oil Clean oil screen and magnet of the drain plugs whenever you exchange the engine oil Change oil filter insert Change fine screen filter (screwed filter) at front pipe (of the frame) Check oil lines for leakage and proper instalment without kinks Check valve clearance Clean spark plug and adjust electrode gap Change spark plug after 10 000 kilometers (6 200 miles) Check ignition point Drain and clean carburetor float chamber Adjust idling Check breather hoses of engine gase and gas tank for correct position without buckles Clean air filter and air filter box Check sprockets, chain guides and chain for wear Maintain chain tension eccentrics Clean and lube chain Check chain tension Check cooling liquid level Check quality of antifreezer Check cooling system for leaks – visual check Check exhaust system for leakage Check exhaust brackets Disassemble and clean spark arrestor discs (USA models) Check brake fluid level front and rear Change brake fluid Check brake pad thickness Check brake discs Check condition and correct instalment of brake hoses Check free play and easy operation of foot brake pedal Check adjustment and function of telescopic fork Check telescopic fork for leaks Change telescopic fork oil Perform a full maintenance job for the telescopic fork Clean dust scrabber of telescopic fork Check steering head bearing clearance / adjust Clean and grease steering head bearings and its seals Check adjustment and funktion of shock absorber Check O-ring of the shock absorber for wear Service the shock absorber Grease nipple of the Pro Lever suspension system Disassemble the Pro Lever suspension system linkage and perform a full maintenance job on it Service swingarm pivot Check spoke tension and join Check wheel bearings for clearance Check shock absorber rubbers on the rear hub Check tire condition and air pressure Check cables for damage and easy working Lube and adjust cables Check the electrical system Check battery holder, battery and connections Check adjustment of headlight Spray ignition lock, emergency off switch, and light switch with contact spray Check all bolts, nuts and hose clamps for proper tightness Grease or lube all pivot points and sliding points at least once a year after washing IF THE MOTORCYCLE IS USED PRIMARILI FOR OFF ROAD RIDING OR COMPETITIVE RACING, THE 5000 KM (3000 MILES) SERVICE NEEDS TO BE CARRIED OUT AFTER EACH RIDE OR RACE before each start DUKE-E 2.98 after 5000 km (3000 miles) or once a year KTM dealer after 2500 km (1500 miles) KTM rider 1st service, after 500 km (300 miles) PERIODIC MAINTENANCE SCHEDULE 11-6D Change oil filter unit at least once a year Clean oil screen and magnet of the drain plugs whenever you exchange the engine oil Check engine oil level after washing Change engine oil IF THE MOTORCYCLE IS USED PRIMARILI FOR OFF ROAD RIDING OR COMPETITIVE RACING, THE 5000 KM (3000 MILES) SERVICE NEEDS TO BE CARRIED OUT AFTER EACH RIDE OR RACE before each start after 2500 km (1500 miles) or 25 hours KTM dealer 1st service, after 1000 km (600 miles) or 10 hours 2.99 620 SX 400/540 SXC 400/620 SC KTM rider after 5000 km (3000 miles) or once a year PERIODIC MAINTENANCE SCHEDULE Change microfilter Check oil lines for leakage and proper instalment Check valve clearance Clean spark plug and adjust electrode gap Change spark plug after 10 000 kilometers (6 200 miles) Check valve clearance Drain and clean carburetor float bowl Check breather hoses of engine gase and gas tank for correct position without buckles Clean air filter and air filter box Check sprockets, chain guides and chain for wear Clean and lube chain Check chain tension Check cooling liquid level Art.-Nr. 3.206.006 -E Check exhaust system for leakage Change exhaust muffler packing (aluminium-muffler) Check exhaust brackets Disassemble and clean spark arrestor discs (USA models) Check brake fluid level front and rear Change brake fluid Check brake pad thickness Check brake discs Check condition and correct instalment of brake hoses Check freeplay and easy operation of hand brake lever and foot brake lever Check adjustment and function of fork Check fork for leaks Loosen breather screws at fork legs (overpressure) Change fork oil Perform a full maintenance job for the telescopic fork Clean dust scrabber on forks Check steering head bearing clearance / adjust Check adjustment and function of shock absorber Check O-ring of the shock absorber for wear Grease lubricating nipple of the Pro Lever suspension system Disassemble the Pro Lever suspension system and perform a full maintenance job on it Servicing swingarm pivots Check tightness of spokes and rim join Check wheel bearings for clearance Check tire condition and air pressure Check cables for damage and easy working Check adjustment of head light Spray ignition lock, emergency OFF switch, short circuit button, and light switch with contact spray Grease or lube all pivot points and sliding components Lube and adjust cables Check all bolts, nuts and hose clamps for proper tightness Servicing the shock absorber Check the electrical system Clean and grease steering head bearings and its seals Repair manual KTM LC4 Check quality of antifreeze Check cooling system for leaks Adjust idling 11-7D Check engine oil level at least once a year after 5000 km (3000 miles) or once a year 1st service, after 500 km (300 miles) IF THE MOTORCYCLE IS USED PRIMARILI FOR OFF ROAD RIDING OR COMPETITIVE RACING, THE 5000 KM (3000 MILES) SERVICE NEEDS TO BE CARRIED OUT AFTER EACH RIDE OR RACE before each start 400/640 LC4 ’99 400/640 LC4 R ’99 620 LC4 Comp.’99 620/640 Supermoto ‘99 10. 98 KTM dealer after washing KTM rider PERIODIC MAINTENANCE SCHEDULE Change engine oil Clean oil screen and magnet of the drain plugs whenever you exchange the engine oil Change oil filter insert Change fine screen filter (screwed filter) at front pipe (of the frame) Check oil lines for leakage and proper instalment without kinks Check valve clearance Clean spark plug and adjust electrode gap Change spark plug after 10 000 kilometers (6 200 miles) Drain and clean carburetor float chamber Check all air supply and ventilation hoses of the engine and of the carburetor for kinks. Clean air filter and air filter box Check sprockets, chain guides and chain for wear Clean and lube chain Check chain tension Check cooling liquid level Check quality of antifreezer Check cooling system for leaks – visual check Adjust idling Check exhaust system for leakage Check exhaust brackets Disassemble and clean spark arrestor discs (USA models) Check brake fluid level front and rear Change brake fluid Check brake pad thickness Check brake discs Check condition and correct instalment of brake hoses Check free play and easy operation of foot brake pedal Check adjustment and function of telescopic fork Check telescopic fork for leaks Loosen bleeder screws at fork legs (overpressure) Change telescopic fork oil Perform a full maintenance job for the telescopic fork Clean dust scrabber of telescopic fork Check steering head bearing clearance / adjust Clean and grease steering head bearings and its seals Check adjustment and function of shock absorber Check O-ring of the shock absorber for wear Grease nipple of the Pro Lever suspension system Disassemble the Pro Lever suspension system linkage and perform a full maintenance job on it Service swingarm pivot Check spoke tension and join Check wheel bearings for clearance Check shock absorber rubbers on the rear hub Check tire condition and air pressure Check cables for damage and easy working Lube and adjust cables Check battery holder, battery and connections Check adjustment of headlight Spray ignition lock, emergency off switch, and light switch with contact spray Check all bolts, nuts and hose clamps for proper tightness Grease or lube all pivot points and sliding points Service the shock absorber Check the electrical system 11-8D KTM rider PERIODIC MAINTENANCE SCHEDULE KTM dealer Repair manual KTM LC4 Art.-Nr. 3.206.006 -E at least once a year 1st service, after 500 km (300 miles) after 5000 km (3000 miles) or once a year Check engine oil level Change engine oil Clean oil screen and magnet of the drain plugs whenever you exchange the engine oil Change oil filter insert Change fine screen filter (screwed filter) at front pipe (of the frame) Check oil lines for leakage and proper instalment without kinks Check valve clearance Clean spark plug and adjust electrode gap Change spark plug after 10 000 kilometers (6 200 miles) Check ignition point Drain and clean carburetor float chamber Adjust idling Check breather hoses of engine case and gas tank for correct position without buckles Clean air filter and air filter box Check sprockets, chain guides and chain for wear Clean and lube chain Check chain tension Check cooling liquid level Check quality of antifreezer Check cooling system for leaks – visual check Check exhaust system for leakage Check exhaust brackets Disassemble and clean spark arrestor discs (USA models) Check brake fluid level front and rear Change brake fluid Check brake pad thickness Check brake discs Check condition and correct instalment of brake hoses Check free play and easy operation of foot brake pedal Check adjustment and function of telescopic fork Check telescopic fork for leaks Loosen bleeder screws at fork legs (overpressure) Change telescopic fork oil Perform a full maintenance job for the telescopic fork Clean dust scrabber of telescopic fork Check steering head bearing clearance / adjust Clean and grease steering head bearings and its seals Check adjustment and function of shock absorber Check O-ring of the shock absorber for wear Service the shock absorber Grease nipple of the Pro Lever suspension system Disassemble the Pro Lever suspension system linkage and perform a full maintenance job on it Service swingarm pivot Check spoke tension and join Check wheel bearings for clearance Check shock absorber rubbers on the rear hub Check tire condition and air pressure Check cables for damage and easy working Lube and adjust cables Check the electrical system Check battery holder, battery and connections Check adjustment of headlight Spray ignition lock, emergency off switch, and light switch with contact spray Check all bolts, nuts and hose clamps for proper tightness Grease or lube all pivot points and sliding points after washing IF THE MOTORCYCLE IS USED PRIMARILI FOR OFF ROAD RIDING OR COMPETITIVE RACING, THE 5000 KM (3000 MILES) SERVICE NEEDS TO BE CARRIED OUT AFTER EACH RIDE OR RACE before each start Adventure 09.98 11-9D PERIODIC MAINTENANCE SCHEDULE KTM rider KTM dealer after 5000 km (3000 miles) or once a year at least once a year Check oil lines for leakage and proper instalment without kinks Check valve clearance Check engine oil level after washing IF THE MOTORCYCLE IS USED FOR COMPETITIVE RACING, THE 5000 KM (3000 MILES) SERVICE NEEDS TO BE CARRIED OUT AFTER EVERY RACE before each start 1st service, after 500 km (300 miles) Duke 5.99 Change engine oil Clean oil screen and magnet of the drain plugs whenever you exchange the engine oil Change oil filter insert Change fine screen filter (screwed filter) at front pipe (of the frame) Clean spark plug and adjust electrode gap Change spark plug after 10 000 kilometers (6 200 miles) Drain and clean carburetor float chamber Check breather hoses of engine gase and gas tank for correct position without buckles Clean air filter and air filter box Check sprockets, chain guides and chain for wear Clean and lube chain Check chain tension Check cooling liquid level Art.-Nr. 3.206.006 -E Check quality of antifreezer Check exhaust system for leakage Check exhaust brackets Clean spark arrestor discs (USA model) Check brake fluid level front and rear Change brake fluid Check brake pad thickness Check wear of brake discs Check condition and correct instalment of brake hoses Check free play and easy operation of foot brake pedal Check adjustment and function of telescopic fork Check telescopic fork for leaks Loosen breather screws at fork legs (overpressure) Change telescopic fork oil Perform a full maintenance job for the telescopic fork Check steering head bearing clearance / adjust Clean and grease steering head bearings and its seals Check adjustment and funktion of shock absorber Repair manual KTM LC4 Check O-ring of the shock absorber for wear Grease nipple of the Pro Lever suspension system Disassemble the Pro Lever suspension system linkage and perform a full maintenance job on it Service swingarm pivot Check spoke tension and join Check wheel bearings for clearance Check tire condition and air pressure Check cables for damage and easy working Check shock absorber rubbers on the rear hub Lube and adjust cables Check battery holder, battery and connections Check adjustment of headlight Spray ignition lock, emergency off switch, and light switch with contact spray Check all bolts, nuts and hose clamps for proper tightness Grease or lube all pivot points and sliding points Service the shock absorber Check the electrical system Maintain chain tension eccentrics Check cooling system for leaks – visual check Adjust idling 11-10D PERIODIC MAINTENANCE SCHEDULE WHEELS CHASSIS BRAKES ADD-ON-PARTS CARBURATOR ENGINE A washed motorcycle can be checked more quickly which saves money! Change engine oil, oil filter, and micro-filter Clean oil screens and magnet of drain plug Check oil lines for damage and kink-less arrangement Check and adjust spark plug, replace it every 10,000 km Check and adjust valve clearance Check engine fastening bolts for tight fit Check carburetor connection boots for cracks and leaks Check idle setting Check bleeder hoses for damage and kink-free arrangement Check cooling system for leaks, antifreeze protection Check exhaust system for leaks and suspension Check actuating cables for damage, smooth operation, and kink-less arrangement, adjust and lubricate Clean air filter and air filter box Check cables for damage and kink-less arrangement Check headlamp adjustment Check electrical system for function; (low/high beams, stop light, turn indicators, tell-tale lamps, speedometer illumination, horn, emergency-off switch) Check brake fluid level, lining thickness, and brake discs Check brake lines for damage and leaks Check/adjust smooth operation, free travel of handbrake/footbrake levers Check bolts of brake system for tight fit Check suspension strut and fork for leaks and proper function Check O-ring of suspension strut for wear Clean dust sleeves Bleed fork legs Check swinging-fork pivot Check/adjust steering-head bearing Lubricate reversing lever Check all chassis bolts for tight fit (fork plates, fork leg, axle nuts/bolts, swinging-fork pivot, reversing lever, suspension strut) Check spoke tension and rim join Check tire condition and inflation pressure Check chain, chain wheels, chain wheel guides for wear, tight fit, and tension Lubricate chain Check wheel bearings and jerk damper for play 620 SC 1. Service after 1000 km or 10 hours after / every 2500 km or 25 hours after / every 5000 km or once a year ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● IMPORTANT RECOMMENDED MAINTENANCE PROCEDURES TO BE PERFORMED BASED ON A SEPARATE SUPPLEMENTARY ORDER every 2500 km or 25 hours Perform complete fork maintenance Perform complete suspension strut maintenance Perform complete reversing lever maintenance Replace glass-fiber yarn packing of main silencer Clean and lubricate steering-head bearing and sealing elements Clean and adjust the carburetor Treat the electrical contacts and switches with contact spray Change brake fluid at least once a year ● every 2 years or 20000 km ● ● ● ● ● ● ● IF MOTORCYCLE IS USED FOR COMPETITION 5000 KM SERVICE SHOULD BE CARRIED OUT AFTER EVERY RACE! SERVICE INTERVALLS SHOULD NEVER BE EXCEED BY MOOR THAN 5 HOURS OR 500 KM. MAINTENANCE WORK DONE BY KTM AUTHORISED WORKSHOPS IS NOT A SUBSTITUTE OF CARE AND CHECKS DONE BY THE RIDER! 11-11D VITAL CHECKS AND CARE PROCEDURES TO BE CONDUCTED BY THE OWNER OR THE MECHANIC Repair manual KTM LC4 Art.-Nr. 3.206.006 -E Check oil level Check brake fluid level Check brake pads for wear Check lighting system for proper operation Check horn for proper operation Lubricate and adjust actuating cables and nipples Bleed fork legs in regular intervals Remove and clean dust sleeves in regular intervals Clean and lubricate chain as necessary Check chain tension Clean air filter and filter box Check tire pressure and wear Check coolant level Check fuel lines for leaks Drain float chamber Verify smooth operation of all controls Check brake performance Btreat exposed metal components (except for the braking and exhaust systems) with wax-based anti-corrosion agents Treat ignition/steering lock and light switch with contact spray Check all bolts, nuts, and hose clamps for their tight fit before each start ● ● ● ● ● after every cleaning for cross country use once a year ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● 11-12D PERIODIC MAINTENANCE SCHEDULE WHEELS CHASSIS BRAKES ADD-ON-PARTS CARBURETOR ENGINE A washed motorcycle can be checked more quickly which saves money! Change engine oil, oil filter, and fine filter Clean oil screens and magnet of drain plug Check oil lines for damage and kink-less arrangement Check and adjust spark plug, replace it every 10,000 km Check and adjust valve clearance Check engine fastening bolts for tight fit Check carburetor connection boots for cracks and leaks Check idle setting Check bleeder hoses for damage and kink-free arrangement Check cooling system for leaks, antifreeze protection Check radiator fan for proper operation Check exhaust system for leaks and suspension Check actuating cables for damage, smooth operation, and kink-less arrangement, and adjust and lubricate them Clean air filter and air filter box Check cables for damage and kink-less arrangement Check headlamp adjustment Check electrical system for function (low/high beams, stop light, turn indicators, headlamp flasher, tell-tale lamps, speedometer illumination, horn, side-stand switch, clutch switch, emergency-off switch) Check brake fluid level, lining thickness, and brake discs Check brake lines for damage and leaks Check/adjust smooth operation, free travel of handbrake/footbrake levers Check bolts of brake system for tight fit Check suspension strut and fork for leaks and proper operation Check O-ring of suspension strut for wear Clean dust sleeves Bleed fork legs Check swinging-fork pivot Check/adjust steering-head bearing Lubricate reversing lever Check all chassis bolts for tight fit (fork plates, fork leg, axle nuts/bolts, swinging-fork pivot, reversing lever, suspension strut) Check spoke tension and rim join Check tire condition and inflation pressure Check chain, chain wheels, chain wheel guides for wear, tight fit, and tension Lubricate chain Check wheel bearings and jerk damper for play 400/640 LC4-E 640 LC4 Adventure 2. Service after 5000 km, then 1. Service every 5000 km or after once a year 1000 km ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● IMPORTANT RECOMMENDED MAINTENANCE PROCEDURES TO BE PERFORMED BASED ON A SEPARATE SUPPLEMENTARY ORDER Perform complete fork maintenance Perform complete suspension strut maintenance Perform complete reversing lever maintenance Clean and lubricate steering-head bearing and sealing elements Clean and adjust the carburetor Treat the electrical contacts and switches with contact spray Treat battery connections with contact grease Change the brake fluid at least once a year ● every 2 years or 20000 km ● ● ● ● ● ● ● IF MOTORCYCLE IS USED FOR COMPETITION 5000 KM SERVICE SHOULD BE CARRIED OUT AFTER EVERY RACE! SERVICE INTERVALLS SHOULD NEVER BE EXCEED BY MOOR THAN 500 KM. MAINTENANCE WORK DONE BY KTM AUTHORISED WORKSHOPS IS NOT A SUBSTITUTE OF CARE AND CHECKS DONE BY THE RIDER! 11-13D VITAL CHECKS AND CARE PROCEDURES TO BE CONDUCTED BY THE OWNER OR THE MECHANIC Repair manual KTM LC4 Art.-Nr. 3.206.006 -E Check oil level Check brake fluid level Check brake pads for wear Check lighting system for proper operation Check horn for proper operation Lubricate and adjust actuating cables and nipples Bleed fork legs in regular intervals Remove and clean dust sleeves in regular intervals Clean and lubricate chain as necessary Check chain tension Clean air filter and filter box Check tire pressure and wear Check coolant level Check fuel lines for leaks Drain float chamber Verify smooth operation of all controls Check brake performance Treat exposed metal components (except for the braking and exhaust systems) with wax-based anti-corrosion agents Treat ignition/steering lock and light switch with contact spray Check all bolts, nuts, and hose clamps for their tight fit before each start ● ● ● ● ● after every cleaning for cross country use once a year ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● 11-14D PERIODIC MAINTENANCE SCHEDULE WHEELS CHASSIS BRAKES ADD-ON-PARTS CARBUTATOR ENGINE A washed motorcycle can be checked more quickly which saves money! Change engine oil, oil filter, and fine filter Clean oil screens and magnet of drain plug Check oil lines for damage and kink-less arrangement Check and adjust spark plug, replace it every 10,000 km Check and adjust valve clearance Check engine fastening bolts for tight fit Check carburetor connection boots for cracks and leaks Check idle setting Check bleeder hoses for damage and kink-free arrangement Check cooling system for leaks, antifreeze protection Check radiator fan for proper function Check exhaust system for leaks and suspension Check actuating cables for damage, smooth operation, and kink-less arrangement, adjust and lubricate Clean air filter and air filter box Check cables for damage and kink-less arrangement Check headlamp adjustment Check electrical system for function (low/high beams, stop light, turn indicators, headlamp flasher, tell-tale lamps, speedometer illumination, horn, side-stand switch, clutch switch, emergency-off switch) Check brake fluid level, lining thickness, and brake discs Check brake lines for damage and leaks Check/adjust smooth operation, free travel of handbrake/footbrake levers Check bolts of brake system for tight fit Check suspension strut and fork for leaks and proper function Check O-ring of suspension strut for wear Clean dust sleeves Bleed fork legs Check swinging-fork pivot Check/adjust steering-head bearing Service eccentric for chain tension Lubricate reversing lever Check all chassis bolts for tight fit (fork plates, fork leg, axle nuts/bolts, swinging-fork pivot, reversing lever, suspension strut) Check tire condition, inflation pressure, and rim condition Check chain, chain wheels, chain wheel guides for wear, tight fit, and tension Lubricate chain Check wheel bearings and jerk damper for play 640 Duke II 1. Service after 1000 km ● ● ● 2. Service after 5000 km, then every 5000 km or once a year ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● IMPORTANT RECOMMENDED MAINTENANCE PROCEDURES TO BE PERFORMED BASED ON A SEPARATE SUPPLEMENTARY ORDER Perform complete fork maintenance Perform complete suspension strut maintenance Perform complete reversing lever maintenance Replace glass-fiber yarn packing of the silencers Clean and lubricate steering-head bearing and sealing elements Clean and adjust the carburetor Treat the electrical contacts and switches with contact spray Treat battery connections with contact grease Change the brake fluid at least once a year ● every 2 years or 20000 km ● ● ● ● ● ● ● ● IF MOTORCYCLE IS USED FOR COMPETITION 5000 KM SERVICE SHOULD BE CARRIED OUT AFTER EVERY RACE! SERVICE INTERVALLS SHOULD NEVER BE EXCEED BY MOOR THAN 500 KM! MAINTENANCE WORK DONE BY KTM AUTHORISED WORKSHOPS IS NOT A SUBSTITUTE OF CARE AND CHECKS DONE BY THE RIDER! 11-15D VITAL CHECKS AND CARE PROCEDURES TO BE CONDUCTED BY THE OWNER OR THE MECHANIC Repair manual KTM LC4 Art.-Nr. 3.206.006 -E Check oil level Check brake fluid level Check brake pads for wear Check lighting system for proper function Check horn for proper function Lubricate and adjust actuating cables and nipples Bleed fork legs in regular intervals Remove and clean dust sleeves in regular intervals Clean and lubricate chain as necessary Check chain tension Clean air filter and filter box Check tire pressure and wear Check coolant level Check fuel lines for leaks Drain float chamber Verify smooth operation of all controls Check braking performance Treat exposed metal components (except for the braking and exhaust systems) with wax-based anti-corrosion agents Treat ignition/steering lock and light switch with contact spray Check all bolts, nuts, and hose clamps for their tight fit before each start ● ● ● ● ● after every cleaning for competition use once a year ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● 11-16D PERIODIC MAINTENANCE SCHEDULE 2002 WHEELS CHASSIS BRAKES ADD-ON-PARTS CARBURATOR ENGINE A washed motorcycle can be checked more quickly which saves money! 1. Service after 1000 km or 10 hours Change engine oil, oil filter, and micro-filter Clean oil screens and magnet of drain plug Check oil lines for damage and kink-less arrangement Check and adjust spark plug, replace every 10,000 km Check and adjust valve clearance Check engine fastening bolts for tight fit ● ● ● Check all engine bolts accessible from the outside for tight fit Check carburetor connection boots for cracks and leaks Check idle setting Check bleeder hoses for damage and kink-free arrangement Check cooling system for leaks, antifreeze protection Check exhaust system for leaks and suspension Check actuating cables for damage, smooth operation, and kink-less arrangement, adjust and lubricate Clean air filter and air filter box Check cables for damage and kink-less arrangement Check headlamp adjustment Check electrical system for function; (low/high beams, stop light, turn indicators, tell-tale lamps, horn) ● Make sure all bolts and nuts are tight. Check brake fluid level, lining thickness, and brake discs Check brake lines for damage and leaks Check/adjust smooth operation, free travel of handbrake/footbrake levers Check bolts of brake system for tight fit Check suspension strut and fork for leaks and proper function Check O-ring of suspension strut for wear Clean dust sleeves Bleed fork legs Check swinging-fork pivot Check/adjust steering-head bearing Lubricate reversing lever Check all chassis bolts for tight fit (fork plates, fork leg, axle nuts/bolts, swinging-fork pivot, reversing lever, suspension strut) Check spoke tension and rim join Check tire condition and inflation pressure ● ● ● ● ● ● Check chain and chain guides for wear, force fit and tension. Check bolts on pinion and chain sprocket for locking devices and a tight fit. Lubricate chain Check wheel bearings and jerk damper for play 625 SC 625 SC SUPERMOTO after / every after / every 5000 km 2500 km or or once a year 25 hours ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● IMPORTANT RECOMMENDED MAINTENANCE PROCEDURES TO BE PERFORMED BASED ON A SEPARATE SUPPLEMENTARY ORDER every 2500 km or 25 hours Perform complete fork maintenance Perform complete suspension strut maintenance Perform complete reversing lever maintenance Replace glass-fiber yarn packing of main silencer Clean and lubricate steering-head bearing and sealing elements Clean and adjust the carburetor Treat the electrical contacts and switches with contact spray Change brake fluid at least once a year ● every 2 years or 20000 km ● ● ● ● ● ● ● IF MOTORCYCLE IS USED FOR COMPETITION 5000 KM SERVICE SHOULD BE CARRIED OUT AFTER EVERY RACE! SERVICE INTERVALLS SHOULD NEVER BE EXCEED BY MOOR THAN 5 HOURS OR 500 KM. MAINTENANCE WORK DONE BY KTM AUTHORISED WORKSHOPS IS NOT A SUBSTITUTE OF CARE AND CHECKS DONE BY THE RIDER! 11-17D VITAL CHECKS AND CARE PROCEDURES TO BE CONDUCTED BY THE OWNER OR THE MECHANIC Repair manual KTM LC4 Art.-Nr. 3.206.006 -E Check oil level Check brake fluid level Check brake pads for wear Check lighting system for proper operation Check horn for proper operation Lubricate and adjust actuating cables and nipples Bleed fork legs in regular intervals Remove and clean dust sleeves in regular intervals Clean and lubricate chain as necessary Check chain tension Clean air filter and filter box Check tire pressure and wear Check coolant level Check fuel lines for leaks Drain float chamber Verify smooth operation of all controls Check brake performance Treat exposed metal components (except for the braking and exhaust systems) with wax-based anti-corrosion agents Treat steering lock and light switch with contact spray Check all bolts, nuts, and hose clamps for tight fit before each start ● ● ● ● ● after every cleaning for cross country use once a year ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● 11-18D PERIODIC MAINTENANCE SCHEDULE 2002 WHEELS CHASSIS BRAKES ADD-ON-PARTS CARBURETOR ENGINE A washed motorcycle can be checked more quickly which saves money! Change engine oil and oil filter Clean oil screens and magnet of drain plug Check oil lines for damage and kink-less arrangement Check and adjust spark plug, replace it every 10,000 km Check and adjust valve clearance Check engine fastening bolts for tight fit Check all engine bolts accessible from the outside for tight fit Check carburetor connection boots for cracks and leaks Check idle setting Check bleeder hoses for damage and kink-free arrangement Check cooling system for leaks, antifreeze protection Check radiator fan for proper operation Check exhaust system for leaks and suspension Check actuating cables for damage, smooth operation, and kink-less arrangement,adjust and lubricate them Clean air filter and air filter box Check cables for damage and kink-less arrangement Check headlamp adjustment Check electrical system for function (low/high beams, stop light, turn indicators,headlamp flasher, tell-tale lamps, speedometer illumination, horn, side-stand switch, clutch switch, emergency-off switch) Make sure all bolts and nuts are tight. Check brake fluid level, lining thickness, and brake discs Check brake lines for damage and leaks Check/adjust smooth operation, free travel of handbrake/footbrake levers Check bolts of brake system for tight fit Check suspension strut and fork for leaks and proper operation Check O-ring of suspension strut for wear Clean fork dust sleeves Bleed fork legs Check swinging-fork pivot Check/adjust steering-head bearing Lubricate reversing lever Check all chassis bolts for tight fit (fork plates, fork leg, axle nuts/bolts, swinging-fork pivot, reversing lever, suspension strut) Check spoke tension and rim joint Check tire condition and inflation pressure Check chain and chain guides for wear, force fit and tension. Check bolts on pinion and chain sprocket for locking devices and a tight fit. Lubricate chain Check wheel bearings and jerk damper for play 640 LC4, LC4 SUPERMOTO 640 LC4 ADVENTURE 2. Service after 1. Service 5000 km, then after every 5000 km or 1000 km once a year ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● IMPORTANT RECOMMENDED MAINTENANCE PROCEDURES TO BE PERFORMED BASED ON A SEPARATE SUPPLEMENTARY ORDER Perform complete fork maintenance Perform complete suspension strut maintenance Perform complete reversing lever maintenance Clean and lubricate steering-head bearing and sealing elements Clean and adjust the carburetor Treat the electrical contacts and switches with contact spray Treat battery connections with contact grease Change the brake fluid at least once a year ● every 2 years or 20000 km ● ● ● ● ● ● ● IF MOTORCYCLE IS USED FOR COMPETITION 5000 KM SERVICE SHOULD BE CARRIED OUT AFTER EVERY RACE! SERVICE INTERVALLS SHOULD NEVER BE EXCEED BY MOOR THAN 500 KM. MAINTENANCE WORK DONE BY KTM AUTHORISED WORKSHOPS IS NOT A SUBSTITUTE OF CARE AND CHECKS DONE BY THE RIDER! 11-19D VITAL CHECKS AND CARE PROCEDURES TO BE CONDUCTED BY THE OWNER OR THE MECHANIC Repair manual KTM LC4 Art.-Nr. 3.206.006 -E Check oil level Check brake fluid level Check brake pads for wear Check lighting system for proper operation Check horn for proper operation Lubricate and adjust actuating cables and nipples Bleed fork legs in regular intervals Remove and clean fork dust sleeves in regular intervals Clean and lubricate chain as necessary Check chain tension Clean air filter and filter box Check tire pressure and wear Check coolant level Check fuel lines for leaks Drain float chamber Check all control elements for smooth running Check brake performance Treat exposed metal components (except for the braking and exhaust systems) with wax-based anti-corrosion agents Treat ignition/steering lock and light switch with contact spray Check all bolts, nuts, and hose clamps for their tight fit before each start ● ● ● ● ● after every cleaning for cross country use once a year ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● 11-20D PERIODIC MAINTENANCE SCHEDULE 2002 WHEELS CHASSIS BRAKES ADD-ON-PARTS CARBUTATOR ENGINE A washed motorcycle can be checked more quickly which saves money! Change engine oil, oil filter, and fine filter Clean oil screens and magnet of drain plug Check oil lines for damage and kink-less arrangement Check and adjust spark plug, replace it every 10,000 km Check and adjust valve clearance Check engine fastening bolts for tight fit Check carburetor connection boots for cracks and leaks Check idle setting Check bleeder hoses for damage and kink-free arrangement Check cooling system for leaks, antifreeze protection Check radiator fan for proper function Check exhaust system for leaks and suspension Check actuating cables for damage, smooth operation, and kink-less arrangement, adjust and lubricate Clean air filter and air filter box Check cables for damage and kink-less arrangement Check headlamp adjustment Check electrical system for function (low/high beams, stop light, turn indicators, headlamp flasher, tell-tale lamps, speedometer illumination, horn, side-stand switch, clutch switch, emergency-off switch) Check brake fluid level, lining thickness, and brake discs Check brake lines for damage and leaks Check/adjust smooth operation, free travel of handbrake/footbrake levers Check bolts of brake system for tight fit Check suspension strut and fork for leaks and proper function Check O-ring of suspension strut for wear Clean dust sleeves Bleed fork legs Check swinging-fork pivot Check/adjust steering-head bearing Service eccentric for chain tension Lubricate reversing lever Check all chassis bolts for tight fit (fork plates, fork leg, axle nuts/bolts, swinging-fork pivot, reversing lever, suspension strut) Check tire condition, inflation pressure, and rim condition Check chain, chain wheels, chain wheel guides for wear, tight fit, and tension Lubricate chain Check wheel bearings and jerk damper for play 640 Duke II 1. Service after 1000 km ● ● ● 2. Service after 5000 km, then every 5000 km or once a year ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● IMPORTANT RECOMMENDED MAINTENANCE PROCEDURES TO BE PERFORMED BASED ON A SEPARATE SUPPLEMENTARY ORDER Perform complete fork maintenance Perform complete suspension strut maintenance Perform complete reversing lever maintenance Replace glass-fiber yarn packing of the silencers Clean and lubricate steering-head bearing and sealing elements Clean and adjust the carburetor Treat the electrical contacts and switches with contact spray Treat battery connections with contact grease Change the brake fluid at least once a year ● every 2 years or 20000 km ● ● ● ● ● ● ● ● IF MOTORCYCLE IS USED FOR COMPETITION 5000 KM SERVICE SHOULD BE CARRIED OUT AFTER EVERY RACE! SERVICE INTERVALLS SHOULD NEVER BE EXCEED BY MOOR THAN 500 KM! MAINTENANCE WORK DONE BY KTM AUTHORISED WORKSHOPS IS NOT A SUBSTITUTE OF CARE AND CHECKS DONE BY THE RIDER! 11-21D VITAL CHECKS AND CARE PROCEDURES TO BE CONDUCTED BY THE OWNER OR THE MECHANIC Repair manual KTM LC4 Art.-Nr. 3.206.006 -E Check oil level Check brake fluid level Check brake pads for wear Check lighting system for proper operation Check horn for proper operation Lubricate and adjust actuating cables and nipples Bleed fork legs in regular intervals Remove and clean fork dust sleeves in regular intervals Clean and lubricate chain as necessary Check chain tension Clean air filter and filter box Check tire pressure and wear Check coolant level Check fuel lines for leaks Drain float chamber Check all control elements for smooth running. Check brake performance Treat exposed metal components (except for the braking and exhaust systems) with wax-based anti-corrosion agents Treat ignition/steering lock and light switch with contact spray Check all bolts, nuts, and hose clamps for their tight fit before each start ● ● ● ● ● after every cleaning once a year ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● 11-22D PERIODIC MAINTENANCE SCHEDULE 2003 1. Service after 1000 km or 10 hours after / every 2500 km or 25 hours Change engine oil, oil filter, and micro-filter Clean oil screens and magnet of drain plug Check oil lines for damage and kink-less arrangement Check and adjust spark plug, replace every 10,000 km Check and adjust valve clearance Check engine fastening bolts for tight fit Make sure all engine bolts accessible from the outside are screwed tight Check carburetor connection boots for cracks and leaks Check idle setting Check bleeder hoses for damage and kink-free arrangement Check cooling system for leaks, antifreeze protection Check exhaust system for leaks and suspension Check actuating cables for damage, smooth operation, and kink-less arrangement, adjust and lubricate Clean air filter and air filter box Check cables for damage and kink-less arrangement Check headlamp adjustment Check electrical system for function; (low/high beams, stop light, turn indicators, tell-tale lamps, horn, emergency-off switch) ● ● ● ● ● Make sure all bolts and nuts are tight Check brake fluid level, lining thickness, and brake discs Check brake lines for damage and leaks Check/adjust smooth operation, free travel of handbrake/footbrake levers Check bolts of brake system for tight fit Check suspension strut and fork for leaks and proper function Check O-ring of suspension strut for wear Clean dust sleeves Bleed fork legs Check swinging-fork pivot Check/adjust steering-head bearing Lubricate reversing lever Check all chassis bolts for tight fit (fork plates, fork leg, axle nuts/bolts, swinging-fork pivot, reversing lever, suspension strut) Check spoke tension and rim join Check tire condition and inflation pressure ● ● ● ● ● ● WHEELS CHASSIS BRAKES ADD-ON-PARTS CARBURATOR ENGINE A washed motorcycle can be checked more quickly which saves money! Check chain and chain guides for wear, force fit and tension Check bolts on pinion and chain sprocket for locking devices and a tight fit Lubricate chain Check wheel bearings and jerk damper for play 625 SXC 660 SMC after / every 5000 km or once a year ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● IMPORTANT RECOMMENDED MAINTENANCE PROCEDURES TO BE PERFORMED BASED ON A SEPARATE SUPPLEMENTARY ORDER every 2500 km or 25 hours Perform complete fork maintenance Perform complete suspension strut maintenance Perform complete reversing lever maintenance Replace glass-fiber yarn packing of main silencer Clean and lubricate steering-head bearing and sealing elements Clean and adjust the carburetor Treat the electrical contacts and switches with contact spray Change brake fluid at least once a year every 2 years or 20000 km ● ● ● ● ● ● ● ● IF MOTORCYCLE IS USED FOR COMPETITION 5000 KM SERVICE SHOULD BE CARRIED OUT AFTER EVERY RACE! SERVICE INTERVALLS SHOULD NEVER BE EXCEED BY MOOR THAN 5 HOURS OR 500 KM. MAINTENANCE WORK DONE BY KTM AUTHORISED WORKSHOPS IS NOT A SUBSTITUTE OF CARE AND CHECKS DONE BY THE RIDER! 11-23D VITAL CHECKS AND CARE PROCEDURES TO BE CONDUCTED BY THE OWNER OR THE MECHANIC Repair manual KTM LC4 Art.-Nr. 3.206.006 -E Check oil level Check brake fluid level Check brake pads for wear Check lighting system for proper operation Check horn for proper operation Lubricate and adjust actuating cables and nipples Bleed fork legs in regular intervals Remove and clean dust sleeves in regular intervals Clean and lubricate chain as necessary Check chain tension Clean air filter and filter box (depending on the dirt accumulation) Check tire pressure and wear Check coolant level Check fuel lines for leaks Drain float chamber Verify smooth operation of all controls Check brake performance Treat exposed metal components (except for the braking and exhaust systems) with wax-based anti-corrosion agents Treat steering lock and light switch with contact spray Check all bolts, nuts, and hose clamps for tight fit before each start ● ● ● ● ● after every cleaning for cross country use once a year ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● 11-24D PERIODIC MAINTENANCE SCHEDULE 2003 WHEELS CHASSIS BRAKES ADD-ON-PARTS CARBURETOR ENGINE A washed motorcycle can be checked more quickly which saves money! 640 LC4, 640 LC4 SUPERMOTO 640 LC4 ADVENTURE 2. Service after 1. Service 5000 km, then after every 5000 km or 1000 km once a year Change engine oil, oil filter, and fine filter Clean oil screens and magnet of drain plug Check oil lines for damage and kink-less arrangement Check and adjust spark plug, replace it every 10,000 km Check and adjust valve clearance Check engine fastening bolts for tight fit Make sure all engine bolts accessible from the outside are screwed tight Check carburetor connection boots for cracks and leaks Check idle setting Check bleeder hoses for damage and kink-free arrangement Check cooling system for leaks, antifreeze protection Check radiator fan for proper operation Check exhaust system for leaks and suspension Check actuating cables for damage, smooth operation, and kink-less arrangement,adjust and lubricate them Clean air filter and air filter box Check cables for damage and kink-less arrangement Check headlamp adjustment Check electrical system for function (low/high beams, stop light, turn indicators,headlamp flasher, tell-tale lamps, speedometer illumination, horn, side-stand switch, clutch switch, emergency-off switch) Make sure all bolts and nuts are tight. Check brake fluid level, lining thickness, and brake discs Check brake lines for damage and leaks Check/adjust smooth operation, free travel of handbrake/footbrake levers Check bolts of brake system for tight fit Check suspension strut and fork for leaks and proper operation Check O-ring of suspension strut for wear Clean fork dust sleeves Bleed fork legs Check swinging-fork pivot Check/adjust steering-head bearing Lubricate reversing lever Check all chassis bolts for tight fit (fork plates, fork leg, axle nuts/bolts, swinging-fork pivot, reversing lever, suspension strut) Check spoke tension and rim joint Check tire condition and inflation pressure Check chain and chain guides for wear, force fit and tension. Check bolts on pinion and chain sprocket for locking devices and a tight fit. Lubricate chain Check wheel bearings and jerk damper for play ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● IMPORTANT RECOMMENDED MAINTENANCE PROCEDURES TO BE PERFORMED BASED ON A SEPARATE SUPPLEMENTARY ORDER Perform complete fork maintenance Perform complete suspension strut maintenance Perform complete reversing lever maintenance Clean and lubricate steering-head bearing and sealing elements Clean and adjust the carburetor Treat the electrical contacts and switches with contact spray Treat battery connections with contact grease Change the brake fluid at least once a year ● every 2 years or 20000 km ● ● ● ● ● ● ● IF MOTORCYCLE IS USED FOR COMPETITION 5000 KM SERVICE SHOULD BE CARRIED OUT AFTER EVERY RACE! SERVICE INTERVALLS SHOULD NEVER BE EXCEED BY MOOR THAN 500 KM. MAINTENANCE WORK DONE BY KTM AUTHORISED WORKSHOPS IS NOT A SUBSTITUTE OF CARE AND CHECKS DONE BY THE RIDER! 11-25D VITAL CHECKS AND CARE PROCEDURES TO BE CONDUCTED BY THE OWNER OR THE MECHANIC Repair manual KTM LC4 Art.-Nr. 3.206.006 -E Check oil level Check brake fluid level Check brake pads for wear Check lighting system for proper operation Check horn for proper operation Lubricate and adjust actuating cables and nipples Bleed fork legs in regular intervals Remove and clean fork dust sleeves in regular intervals Clean and lubricate chain as necessary Check chain tension Clean air filter and filter box (depending on the dirt accumulation) Check tire pressure and wear Check coolant level Check fuel lines for leaks Drain float chamber Check all control elements for smooth running. Check brake performance Treat exposed metal components (except for the braking and exhaust systems) with wax-based anti-corrosion agents Treat ignition/steering lock and light switch with contact spray Check all bolts, nuts, and hose clamps for their tight fit before each start ● ● ● ● ● after every cleaning for cross country use once a year ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● 11-26D PERIODIC MAINTENANCE SCHEDULE 2003 WHEELS CHASSIS BRAKES ADD-ON-PARTS CARBUTATOR ENGINE A washed motorcycle can be checked more quickly which saves money! Change engine oil, oil filters, and fine filter Clean oil screens and magnet of drain plug Check oil lines for damage and kink-less arrangement Check and adjust spark plug, replace it every 10,000 km Check and adjust valve clearance Check engine fastening bolts for tight fit Check carburetor connection boots for cracks and leaks Check idle setting Check bleeder hoses for damage and kink-free arrangement Check cooling system for leaks, antifreeze protection Check radiator fan for proper function Check exhaust system for leaks and suspension Check actuating cables for damage, smooth operation, and kink-less arrangement, adjust and lubricate Clean air filter and air filter box Check cables for damage and kink-less arrangement Check headlamp adjustment Check electrical system for function (low/high beams, stop light, turn indicators, headlamp flasher, tell-tale lamps, speedometer illumination, horn, side-stand switch, clutch switch, emergency-off switch) Check brake fluid level, lining thickness, and brake discs Check brake lines for damage and leaks Check/adjust smooth operation, free travel of handbrake/foot brake levers Check bolts of brake system for tight fit Check suspension strut and fork for leaks and proper function Check O-ring of suspension strut for wear Clean dust sleeves Bleed fork legs Check swinging-fork pivot Check/adjust steering-head bearing Service eccentric for chain tension Lubricate reversing lever Check all chassis bolts for tight fit (fork plates, fork leg, axle nuts/bolts, swinging-fork pivot, reversing lever, suspension strut) Check tire condition, inflation pressure, and rim condition Check chain, chain wheels, chain wheel guides for wear, tight fit, and tension Lubricate chain Check wheel bearings and jerk damper for play 640 Duke 1st Service after 1000 km ● ● ● 2nd Service after 5000 km, then every 5000 km or once a year ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● IMPORTANT RECOMMENDED MAINTENANCE PROCEDURES TO BE PERFORMED BASED ON A SEPARATE SUPPLEMENTARY ORDER Perform complete fork maintenance Perform complete suspension strut maintenance Perform complete reversing lever maintenance Replace glass-fiber yarn packing of the silencers Clean and lubricate steering-head bearing and sealing elements Clean and adjust the carburetor Treat the electrical contacts and switches with contact spray Treat battery connections with contact grease Change the brake fluid at least once a year ● every 2 years or 20000 km ● ● ● ● ● ● ● ● IF MOTORCYCLE IS USED FOR COMPETITION 5000 KM SERVICE SHOULD BE CARRIED OUT AFTER EVERY RACE! SERVICE INTERVALLS SHOULD NEVER BE EXCEED BY MORE THAN 500 KM! MAINTENANCE WORK DONE BY KTM AUTHORISED WORKSHOPS IS NOT A SUBSTITUTE OF CARE AND CHECKS DONE BY THE RIDER! 11-27D VITAL CHECKS AND CARE PROCEDURES TO BE CONDUCTED BY THE OWNER OR THE MECHANIC Repair manual KTM LC4 Art.-Nr. 3.206.006 -E Check oil level Check brake fluid level Check brake pads for wear Check lighting system for proper operation Check horn for proper operation Lubricate and adjust actuating cables and nipples Bleed fork legs in regular intervals Remove and clean fork dust sleeves in regular intervals Clean and lubricate chain as necessary Check chain tension Clean air filter and filter box Check tire pressure and wear Check coolant level Check fuel lines for leaks Drain float chamber Check all control elements for smooth running. Check brake performance Treat exposed metal components (except for the braking and exhaust systems) with wax-based anti-corrosion agents Treat ignition/steering lock and light switch with contact spray Check all bolts, nuts, and hose clamps for their tight fit before each start ● ● ● ● ● after every cleaning once a year ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● 12-1D 12 WIRING DIAGRAMS Repair manual KTM LC4 Art.-Nr. 3.206.006 -E INDEX MODEL1998 WIRING DIAGRAM WIRING DIAGRAM WIRING DIAGRAM WIRING DIAGRAM WIRING DIAGRAM WIRING DIAGRAM WIRING DIAGRAM WIRING DIAGRAM WIRING DIAGRAM WIRING DIAGRAM 400 400 400 400 640 640 640 620 400 640 / 540 SXC . . . . . . . . . . . . . . . . . . . . . .12-3 / 620 SC (For Competition) . . . . . . . . .12-5 / 620 SC (For Australia) . . . . . . . . . . . .12-7 / 620 SC (For Germany) . . . . . . . . . . . .12-9 LC4 (For USA) . . . . . . . . . . . . . . . . . . .1211 ADVENTURE-R (Dell Orto) . . . . . . . . .12-13 DUKE-E . . . . . . . . . . . . . . . . . . . . . . .12-15 LC4 COMPETITION . . . . . . . . . . . . . .12-17 LC4 . . . . . . . . . . . . . . . . . . . . . . . . .12-19 LC4 . . . . . . . . . . . . . . . . . . . . . . . . .12-21 MODEL 1999 WIRING DIAGRAM WIRING DIAGRAM WIRING DIAGRAM WIRING DIAGRAM WIRING DIAGRAM WIRING DIAGRAM WIRING DIAGRAM WIRING DIAGRAM WIRING DIAGRAM WIRING DIAGRAM WIRING DIAGRAM 400 400 400 400 640 640 640 620 400 640 640 / 540 SXC . . . . . . . . . . . . / 540 SXC (Australia) . . . . / 620 SC . . . . . . . . . . . . / 620 SC (Australia) . . . . . ADVENTURE-R (Dell Orto) ADVENTURE-R (Mikuni) . . DUKE . . . . . . . . . . . . . . . LC4 COMPETITION . . . . . LC4 . . . . . . . . . . . . . . . . LC4, SUPERMOTO . . . . . . LC4 (USA) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-23 .12-25 .12-27 .12-29 .12-13 .12-31 .12-33 .12-17 .12-19 .12-21 .12-11 MODEL 2000 WIRING DIAGRAM WIRING DIAGRAM WIRING DIAGRAM WIRING DIAGRAM WIRING DIAGRAM WIRING DIAGRAM 400 640 640 400 640 400 / 620 SC / 620 SC SUPERMOTO ADVENTURE-R . . . . . . . . . . . . DUKE . . . . . . . . . . . . . . . . . . . LC4-E . . . . . . . . . . . . . . . . . . . LC4-E, SUPERMOTO . . . . . . . . / 640 LC4-E (USA) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-27 .12-31 .12-33 .12-19 .12-21 .12-35 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-2D INDEX MODEL 2001 WIRING DIAGRAM WIRING DIAGRAM WIRING DIAGRAM WIRING DIAGRAM WIRING DIAGRAM 620 640 640 400 640 SC / 620 SC SUPERMOTO . . LC4 ADVENTURE . . . . . . . . DUKE . . . . . . . . . . . . . . . . . LC4-E, 400 / 640 LC4-E USA LC4-E, SUPERMOTO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-37 .12-39 .12-41 .12-43 .12-45 MODEL 2002 WIRING DIAGRAM WIRING DIAGRAM WIRING DIAGRAM WIRING DIAGRAM 625 640 640 640 SC / 625 SC SUPERMOTO . LC4 ADVENTURE . . . . . . . DUKE . . . . . . . . . . . . . . . . LC4, 640 LC4 SUPERMOTO . . . . . . . . . . . . . . . . . . . . . . . . .12-47 .12-49 .12-51 .12-53 . . . . Repair manual KTM LC4 Art.-Nr. 3.206.006 -E WIRING DIAGRAM 640 LC4, 640 LC4 SUPERMOTO USA . . . .12-55 MODEL 2003 WIRING DIAGRAM WIRING DIAGRAM WIRING DIAGRAM WIRING DIAGRAM WIRING DIAGRAM 625 640 640 640 660 SXC . . . . . . . . . . . . . . . . . LC4, 640 LC4 SUPERMOTO LC4 ADVENTURE . . . . . . . DUKE . . . . . . . . . . . . . . . . SMC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-57 .12-59 .12-61 .12-63 .12-64 12-3D Repair manual KTM LC4 Art.-Nr. 3.206.006 -E 12-4D 12-5D Repair manual KTM LC4 Art.-Nr. 3.206.006 -E 12-6D 12-7D Repair manual KTM LC4 Art.-Nr. 3.206.006 -E 12-8D 12-9D Repair manual KTM LC4 Art.-Nr. 3.206.006 -E 12-10D KTM 400 / 640 SC 1998 12-11D Repair manual KTM LC4 Art.-Nr. 3.206.006 -E 12-12D 12-13D Repair manual KTM LC4 Art.-Nr. 3.206.006 -E 12-14D 12-15D Repair manual KTM LC4 Art.-Nr. 3.206.006 -E 12-16D 12-17D Repair manual KTM LC4 Art.-Nr. 3.206.006 -E 12-18D 12-19D Repair manual KTM LC4 Art.-Nr. 3.206.006 -E 12-20D 12-21D Repair manual KTM LC4 Art.-Nr. 3.206.006 -E 12-22D 12-23D Repair manual KTM LC4 Art.-Nr. 3.206.006 -E 12-24D 12-25D Repair manual KTM LC4 Art.-Nr. 3.206.006 -E 12-26D 12-27D Repair manual KTM LC4 Art.-Nr. 3.206.006 -E 12-28D 12-29D Repair manual KTM LC4 Art.-Nr. 3.206.006 -E 12-30D 12-31D Repair manual KTM LC4 Art.-Nr. 3.206.006 -E 12-32D 12-33D Repair manual KTM LC4 Art.-Nr. 3.206.006 -E 12-34D 12-35D 400/640 LC4 USA Repair manual KTM LC4 400/640 LC4 USA 2000 Art.-Nr. 3.206.006 -E 12-36D 12-37D Repair manual KTM LC4 Art.-Nr. 3.206.006 -E 12-38D KTM 620 SC 2001 12-39D Repair manual KTM LC4 Art.-Nr. 3.206.006 -E 12-40D 12-41D Repair manual KTM LC4 Art.-Nr. 3.206.006 -E 12-42D 12-43D Repair manual KTM LC4 Art.-Nr. 3.206.006 -E 12-44D 12-45D Repair manual KTM LC4 KTM 640 LC4-E 2001 Art.-Nr. 3.206.006 -E 12-46D 12-47D SERVICE 625 SuperComp. 2002 Repair manual KTM LC4 Art.-Nr. 3.206.006 -E 12-48D KTM 625 SUPER COMPETITION 2002 12-49D SERVICE 640 LC4 ADVENTURE Repair manual KTM LC4 KTM 640 LC4 ADVENTURE 2002 Art.-Nr. 3.206.006 -E 12-50D 12-51D SERVICE DUKE 2002 Repair manual KTM LC4 Art.-Nr. 3.206.006 -E KTM DUKE 2002 12-52D 12-53D SERVICE SERVICE ax MOTORCYCLE Kabelstrangnummer: Modell 640LC4-E LC4 2002 2002 400/640 Datum, Name: DIV. LÄNDER Dateiname: 10.05.01 KE LC42002 br 1 4 10 s br g bl br br 2 v br ge-bl ge-bl br w v 3 Land: vorne: 584.11.175.300 hinten: 584.11.176.200 7 33 w 9 s 8 bl 6 g-s 5 ge-s 11 START NOT- g-s ge g o bl r-w ge w g-r g-s g-br bl-r bl-s g r-br 40 br ge g bl w ge-bl o v s gr br v ge-bl ge-s g-s bl s w br 47 11 11 ge-bl g-r o r o r-w ge 42 44 g-r r-s s-o bl-s ge-bl br bl-w 31 ge-bl 14 29 30 r o o ge-bl 31 s ge-r ge-r ge-bl br v ge-bl ge-s g-s bl s w br 12 s-w o bl s s-ge AUS 35 ELECTRONIC POWERCONTROL 28 ge-bl r-s br 43 49 s-o 50 bl-s ge-bl gr g-s ge 48 16 g-w 15 g-s 17 ge-s 18 28 ge-bl o o 53 br 20 29 ge-s g-s s-o bl-s 23 ge-bl 21 bl-w 13 36 br KOKUSAN r s-w ge ge ge s g-s 48 19 g-w ge-s g-s s-o bl-s 52 KOKUSAN br 41 ge-r br 28 r-w br 13 br 37 g-w br w v s s r g w ge-r br 38 ge r-s s-r M bl-w s-r r-s s-w o g w s 32 34 45 22 G 13 46 KOKUSAN 12V 200W s v 13 25 39 26 br 51 br 24 g-w br w v s 30 27 KOKUSAN 12-54D Repair manual KTM LC4 Spanisch KTM 640 LC4 2002 2002 KTM 400/640 LC4-E Art.-Nr. 3.206.006 -E Deutsch Englisch 1 Scheinwerfer 2 Standlicht 3 Blinker li vo 4 Blinker re vo 5 Temperaturkontrolle 6 Leerlaufanzeige 7 Tachobeleuchtung 8 Fernlichtkontrolle 9 Blinkerkontrolle 10 Z ndschlo§ 11 Sicherung 10A 12 zum Kombischalter 13 Masseanschlu§ 14 Blinkgeber 15 Horn 16 Bremslichtsch. vo 17 Leerlaufschalter (N) 18 Thermoschalter 19 Bremslichtsch. hi 20 Z ndkerze 21 Z ndspule 22 Generator 23 Regelgleichrichter 24 Blinker li hi 25 Blinker re hi 26 Brems-Schlu§licht 27 CDI-Einheit 28 2-pol.Stecker 29 4-pol.Stecker 30 6-pol.Stecker 31 9-pol.Stecker 32 Hauptsicherung 20A 33 Starttast.Notaussch. 34 Batterie 12V 8Ah 35 EPC 36 L ftermotor 37 Startrelaise 38 Startermotor 39 Kennzeichenbeleuchtung 40 Kupplungsschalter 41 Thermoschalter 42 Starterhilfsrelais 43 Vergaserschalter 44 Magnetventil 45 Kondensator 46 Impulsgeber 47 12-pol.Stecker 48 Diode 49 Kontaktstift 3.Gang 50 Kontaktstift 2.Gang 51 3-pol.Stecker 52 Seitenst nderrelais 53 Seitenst nderschalter Italienisch 1 headlight 2 parking light 3 blinker left front 4 blinker right front 5 temperature control 6 neutral 7 tachometer light 8 high beam control 9 blink control 10 ignition switch 11 fuse 10A 12 to combinat. switch 13 ground connection 14 blink signal system 15 horn 16 stoplight switch f. 17 idle switch (N) 18 temperature switch 19 stoplight switch r. 20 spark plug 21 ignition coil 22 generator 23 regulator-rectifier 24 blinker left rear 25 blinker right rear 26 rear-stoplight 27 CDI-unit 28 multip.cont.plug (2) 29 multip.cont.plug (4) 30 multip.cont.plug (6) 31 multip.cont.plug (9) 32 mainfuse 20A 33 run-off/start switch 34 battery 12V 8Ah 35 EPC 36 fan motor 37 starter relay 38 starter engine 39 licence plate lighting 40 clutch switch 41 temperature switch 42 startar auxil. relay 43 carburetor switch 44 magnetic valve 45 capacitor 46 pulser coil 47 multip.cont.plug (12) 48 diode 49 gear switch 3rd gear 50 gear switch 2th gear 51 multip.cont.plug (3) 52 sidestand relay 53 side stand switch 1 faro 2 luz de posicion 3 interm. izquierdo delantero 4 intermitente derecho delantero 5 control temperatura 6 indicador punto muerto 7 luz tacometro 8 lampara aviso luces largas 9 lampara aviso intermitentes 10 llave de contacto 11 fusible 10A 12 interruptor combinado 13 conector a masa 14 conjunto del intermitente 15 claxon 16 interruptor 17 interruptor punto muerto 18 interruptor temperatura Franz sisch 1 faro 2 luce di posizione 3 lampegg. ant. sn. 4 lampegg. ant. dx. 5 controllo temperatura 6 indicat.marcia folle 7 luce di tachimetro 8 spia abbagliante 9 spia lampeggiatori 10 int. accensione 11 fusibile 10A 12 multicomando 13 collegam. a massa 14 trasmett. di lampeg. 15 clacson 16 int.luce arresto ant. 17 interr.luce folle (N) 18 int. temperatura 19 int.luce arresto post 20 candela 21 bobina d’accens. 22 dinamo 23 regolatore di tens 24 lampegg. post. sn. 25 lampegg. post. dx. 26 fanal.post.di freno 27 CDI-seatola 28 connettore a 2 poli 29 connettore a 4 poli 30 connettore a 6 poli 31 connettore a 9 poli 32 fusibile principale 20A 33 disinseritor/partire 34 batteria 12V 8Ah 35 EPC 36 ventilatore 37 rele d’avviamento 38 mot.d’avviamento elettr. 39 illuminat.de.targa 40 interrutore frizione 41 int. temperatura 42 rele avviam. ausiliario 43 interrutore carburatore 44 valvola elettromagnetica 45 condensatore 46 trasmettitore d’impulsi 47 connettore a 12 poli 48 diodo 49 3.secondo marcia 50 2.secondo marcia 51 connettore a 3 poli 52 rele del cavalleto later 53 int del cavalleto later 1 phare 2 feu de position 3 clignoteur av. gauche 4 clignoteur av. droit 5 temoin de temperature 6 ind.de point mort 7 eclair.comp.vitesse 8 temoin de feu route 9 temoin de clignoteur 10 contact.d’allum. 11 fusible 10A 12 vers commutateur 13 masse 14 centrale clignot. 15 klaxon 16 cont.av de stop 17 contact.pt.mort (N) 18 contact. de temperature 19 contact.arr.de stop 20 bougie 21 bobine d’allumage 22 generateur 23 regulat.redresseur 24 clign.arr.gauche 25 clign.arr.droit 26 feu arr.et de stop 27 boitier CDI 28 connect.multiple (2) 29 connect.multiple (4) 30 connect.multiple (6) 31 connect.multiple (9) 32 fusible principal 20A 33 bout.de demar/arr.d’urg 34 batterie 12V 8Ah 35 EPC 36 ventilateur 37 relaise de demarreur 38 demarreur electrique 39 ecl.plaque d.immat. 40 contact.de embrayage 41 contact.de temperature 42 relaise auxi demarrage 43 contact.de carburateur 44 electrovanne 45 condensateur 46 capteur 47 connect.multiple (12) 48 diode 49 cont.d.boite d.vites.(3) 50 cont.d.bolte.d.vites.(2) 51 connect.multiple (3) 52 relaise com de bequ lat 53 commut de bequille later 37 rele de arranque 38 motor de arranque 39 luz plaza de matricula 40 interruptor de embraque 41 interruptor temperatura 42 rele del arranque 43 interruptor de carburador 44 valvola magnetica 45 condensador 46 generado de impulsos 47 conector multiple (12) 48 diodo 49 interruptor de cambio (3) 50 interruptor de cambio (2) 51 conector multiple (3) 52 rele del caballete lateral 53 int.del caballete lateral 19 interruptor luz de frendo tras 20 bujia 21 bobina de encendido 22 generador 23 regulador de tension 24 intermitente izquierdo trasero 25 intermitente derecho trasero 26 luz de freno trasero 27 unidad cdi 28 conecdor multiple (2) 29 conector multiple (4) 30 conector multiple (6) 31 conector multiple (9) 32 fusible principal 20A 33 boton de arranque par.de urg. 34 bateria 12V 8 Ah 35 EPC 36 ventilador electrica Start- Notaus- Schalter Deutsch bl blau br braun ge gelb gr grau g gr n o orange r rot ra rosa s schwarz v violett w wei§ Englisch bl blue br brown ge yellow gr grey g green o orange r red ra pink s black v violet w white Italienisch bl blu br marrone ge giallo gr grigio g verde o arancione r rosso ra rosa s nero v violetto w bianco Franz sisch bl bleu br brun ge jaune gr gris g vert o orange r rouge ra rose s noir v violet w blanc Kombischalter Spanisch bl azul br marron ge amarillo gr gris g verde o naranja r rojo ra rosado s negro v violeta w blanco br ge w bl- blr s gbr g gs o Domino sge bl s sw rw bl TURN L TURN R Z ndschlo§ (Typ Zadi) LIGHTS o H LO H HI HORN PASSING g ge gs 12-55D SERVICE SERVICE ax MOTORCYCLE Kabelstrangnummer: Modell Datum, Name: USA Dateiname: 10.05.01 KE LC42002 br 1 4 10 s br g bl br br 2 v br ge-bl ge-bl br w v 3 Land: vorne: 584.11.175.300 hinten: 584.11.176.200 640 LC4USA USA 2002 640 LC4-E 2002 7 33 w 9 s 8 bl 6 g-s 5 ge-s 11 START NOT- g-s ge g o bl r-w ge w g-r g-s g-br bl-r bl-s g r-br 40 br ge g bl w ge-bl o v s gr br v ge-bl ge-s g-s bl s w br 47 11 11 ge-bl g-r 31 ge-bl 14 29 30 r o o ge-bl 31 s ge-r ge-r ge-bl br v ge-bl ge-s g-s bl s w br 12 s-w o bl s s-ge AUS o r o r-w ge 42 28 ge-bl r-s br ge-bl gr s-o bl-s g-s ge 48 16 g-w 15 g-s 17 ge-s 18 28 ge-bl o o 53 br 20 29 ge-s g-s s-o bl-s 23 ge-bl 21 bl-w 13 36 br KOKUSAN r s-w ge ge ge s g-s 48 19 g-w ge-s g-s s-o bl-s 52 KOKUSAN br 41 ge-r br 28 r-w br 13 br 37 g-w br w v s s r g w ge-r br 38 ge r-s s-r M bl-w s-r r-s s-w o g w s 32 34 45 22 G 13 46 KOKUSAN 12V 200W s v 13 25 39 26 br 51 br 24 g-w br w v s 30 27 KOKUSAN 12-56D Repair manual KTM LC4 Spanisch LC4USA USA2002 2002 KTMKTM 640 640 LC4-E Art.-Nr. 3.206.006 -E Deutsch Englisch Italienisch Franz sisch 1 Scheinwerfer 2 Standlicht 3 Blinker li vo 4 Blinker re vo 5 Temperaturkontrolle 6 Leerlaufanzeige 7 Tachobeleuchtung 8 Fernlichtkontrolle 9 Blinkerkontrolle 10 Z ndschlo§ 11 Sicherung 10A 12 zum Kombischalter 13 Masseanschlu§ 14 Blinkgeber 15 Horn 16 Bremslichtsch. vo 17 Leerlaufschalter (N) 18 Thermoschalter 19 Bremslichtsch. hi 20 Z ndkerze 21 Z ndspule 22 Generator 23 Regelgleichrichter 24 Blinker li hi 25 Blinker re hi 26 Brems-Schlu§licht 27 CDI-Einheit 28 2-pol.Stecker 29 4-pol.Stecker 30 6-pol.Stecker 31 9-pol.Stecker 32 Hauptsicherung 20A 33 Starttast.Notaussch. 34 Batterie 12V 8Ah 1 headlight 2 parking light 3 blinker left front 4 blinker right front 5 temperature control 6 neutral 7 tachometer light 8 high beam control 9 blink control 10 ignition switch 11 fuse 10A 12 to combinat. switch 13 ground connection 14 blink signal system 15 horn 16 stoplight switch f. 17 idle switch (N) 18 temperature switch 19 stoplight switch r. 20 spark plug 21 ignition coil 22 generator 23 regulator-rectifier 24 blinker left rear 25 blinker right rear 26 rear-stoplight 27 CDI-unit 28 multip.cont.plug (2) 29 multip.cont.plug (4) 30 multip.cont.plug (6) 31 multip.cont.plug (9) 32 mainfuse 20A 33 run-off/start switch 34 battery 12V 8Ah 1 faro 2 luce di posizione 3 lampegg. ant. sn. 4 lampegg. ant. dx. 5 controllo temperatura 6 indicat.marcia folle 7 luce di tachimetro 8 spia abbagliante 9 spia lampeggiatori 10 int. accensione 11 fusibile 10A 12 multicomando 13 collegam. a massa 14 trasmett. di lampeg. 15 clacson 16 int.luce arresto ant. 17 interr.luce folle (N) 18 int. temperatura 19 int.luce arresto post 20 candela 21 bobina d’accens. 22 dinamo 23 regolatore di tens 24 lampegg. post. sn. 25 lampegg. post. dx. 26 fanal.post.di freno 27 CDI-seatola 28 connettore a 2 poli 29 connettore a 4 poli 30 connettore a 6 poli 31 connettore a 9 poli 32 fusibile principale 20A 33 disinseritor/partire 34 batteria 12V 8Ah 1 phare 2 feu de position 3 clignoteur av. gauche 4 clignoteur av. droit 5 temoin de temperature 6 ind.de point mort 7 eclair.comp.vitesse 8 temoin de feu route 9 temoin de clignoteur 10 contact.d’allum. 11 fusible 10A 12 vers commutateur 13 masse 14 centrale clignot. 15 klaxon 16 cont.av de stop 17 contact.pt.mort (N) 18 contact. de temperature 19 contact.arr.de stop 20 bougie 21 bobine d’allumage 22 generateur 23 regulat.redresseur 24 clign.arr.gauche 25 clign.arr.droit 26 feu arr.et de stop 27 boitier CDI 28 connect.multiple (2) 29 connect.multiple (4) 30 connect.multiple (6) 31 connect.multiple (9) 32 fusible principal 20A 33 bout.de demar/arr.d’urg 34 batterie 12V 8Ah 36 L ftermotor 37 Startrelaise 38 Startermotor 39 Kennzeichenbeleuchtung 40 Kupplungsschalter 41 Thermoschalter 42 Starterhilfsrelais 36 fan motor 37 starter relay 38 starter engine 39 licence plate lighting 40 clutch switch 41 temperature switch 42 startar auxil. relay 36 ventilatore 37 rele d’avviamento 38 mot.d’avviamento elettr. 39 illuminat.de.targa 40 interrutore frizione 41 int. temperatura 42 rele avviam. ausiliario 36 ventilateur 37 relaise de demarreur 38 demarreur electrique 39 ecl.plaque d.immat. 40 contact.de embrayage 41 contact.de temperature 42 relaise auxi demarrage 45 Kondensator 46 Impulsgeber 47 12-pol.Stecker 48 Diode 45 capacitor 46 pulser coil 47 multip.cont.plug (12) 48 diode 45 condensatore 46 trasmettitore d’impulsi 47 connettore a 12 poli 48 diodo 45 condensateur 46 capteur 47 connect.multiple (12) 48 diode 51 3-pol.Stecker 52 Seitenst nderrelais 53 Seitenst nderschalter 51 multip.cont.plug (3) 52 sidestand relay 53 side stand switch 51 connettore a 3 poli 52 rele del cavalleto later 53 int del cavalleto later 51 connect.multiple (3) 52 relaise com de bequ lat 53 commut de bequille later 1 faro 2 luz de posicion 3 interm. izquierdo delantero 4 intermitente derecho delantero 5 control temperatura 6 indicador punto muerto 7 luz tacometro 8 lampara aviso luces largas 9 lampara aviso intermitentes 10 llave de contacto 11 fusible 10A 12 interruptor combinado 13 conector a masa 14 conjunto del intermitente 15 claxon 16 interruptor 17 interruptor punto muerto 18 interruptor temperatura 37 rele de arranque 38 motor de arranque 39 luz plaza de matricula 40 interruptor de embraque 41 interruptor temperatura 42 rele del arranque 19 interruptor luz de frendo tras 20 bujia 21 bobina de encendido 22 generador 23 regulador de tension 24 intermitente izquierdo trasero 25 intermitente derecho trasero 26 luz de freno trasero 27 unidad cdi 28 conecdor multiple (2) 29 conector multiple (4) 30 conector multiple (6) 31 conector multiple (9) 32 fusible principal 20A 33 boton de arranque par.de urg. 34 bateria 12V 8 Ah 45 condensador 46 generado de impulsos 47 conector multiple (12) 48 diodo 51 conector multiple (3) 52 rele del caballete lateral 53 int.del caballete lateral 36 ventilador electrica Start- Notaus- Schalter Deutsch bl blau br braun ge gelb gr grau g gr n o orange r rot ra rosa s schwarz v violett w wei§ Englisch bl blue br brown ge yellow gr grey g green o orange r red ra pink s black v violet w white Italienisch bl blu br marrone ge giallo gr grigio g verde o arancione r rosso ra rosa s nero v violetto w bianco Franz sisch bl bleu br brun ge jaune gr gris g vert o orange r rouge ra rose s noir v violet w blanc Kombischalter Spanisch bl azul br marron ge amarillo gr gris g verde o naranja r rojo ra rosado s negro v violeta w blanco br ge bl- blw r s gbr g gs o Domino sge bl s sw rw bl TURN L TURN R Z ndschlo§Æ (Typ Zadi) LIGHTS o H LO H HI HORN PASSING g ge gs 12-57D Repair manual KTM LC4 Art.-Nr. 3.206.006 -E 12-58D 12-59D 640 LC4 2003 Repair manual KTM LC4 KTM 640 LC4 2003 Art.-Nr. 3.206.006 -E 12-60D 12-61D Repair manual KTM LC4 Art.-Nr. 3.206.006 -E 12-62D flasher control lamp temperature control lamp ye-bl ye-bu left front flasher right front flasher bl pu v speedometer n idle control lamp tachometer headlight bu br gn-bl ye-bu br bl pu br br wh ye-bu bu-wh wh br wh br or br gn wh ye-bl gn-bl br bu-wh wh bu gn-bl ye 2nd pi 3th br-pi br neutral switch 2nd gear 3th gear temperature sensor t∞ bu-re pu front brake switch 640-Duke 03 sidestand switch br ye N ye-wh ye-br bl-wh or or ye-bu M cooling fan A 10 A 10 A 10 fuse box ye-bu re-wh br bl-or or br wiring diagram EPC wh wh or G bu ye-bu ye-bu bl pu or gn bu gr ye-bl gn-wh pi clutch switch horn ye br driving light lamp gn-bl gn re-ye ye re-gn 0 ye-bu head light flascher ye gn ye-bl gn-re gn-br ye-br or bu-bl bu-bl bl or-bl gr gn-bl bl-bu or re ignition coil bl bl-or bu-wh br 1 starter motor ye-re M octane selector ignition switch br-bl br C_AF1/4 + gn battery ye TPS bl or ye re re-wh main harness - 587.11.075.100 cockpit - 587.11.082.000 rear - 587.11.076.200 fuse box - 587.11.087.000 Pick up capacitor _ 20 A start relay br light switch br-bl re-gn diode 2 bu-wh temperature switch br-bl or-bl diode pi re start/stop switch ye re-wh bl re-wh bu ye bl re wh re-wh flasher relay bu-bl C re-ye ye D re gn I re Art.-Nr. 3.206.006 -E br-bl br re wh high/low beam switch horn switch flasher switch bu Repair manual KTM LC4 gn-wh wh br wh bl br pu gn-wh ye-bu rear brake switch start auxillary relay br re 3 left raer flasher licence plate lamp right rear flasher generator G U regulator-rectifier 12-63D rear light/brakelight 12-64D 660 SMC 2003 Repair manual KTM LC4 Art.-Nr. 3.206.006 -E 12-65D KTM 660 SMC 2003
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